I would suggest if he has had egr AND manifold replaced then it is most probably going to be the 1.8 FORD engine as it's the only focus tdci engine that uses a combined egr/manifold assembly.

Anyway, i would suggest testing of the glow-plugs & go from there. However it could be literally be anything, all modern diesel engines are very complicated.

& as you already know ford motor company will not be interested at all, it's a five year old car ffs, cars have problems, even five year old diesel ones!!!!!!!!!!!!!!!!!!!!!!!!

And someone said all four injectors don't all go at once, correct they dont. All four will wear at the same rate though, and when you get one fail thats normally when you get all four tested, usually you find one with solenoid circuit fault and the other three with leak-off problems. Hence the need for four injectors.