Hi all,
 
Well the saga continues. I took the car back into ford and they kept the car for two days charged me too much money and basically told me they didn't know what the problem was.. other than it is fuel system related.
 
I have since fitted a new fuel pump driver module and just tonight a 2nd hand fuel rail pressure sensor... unfortunately neither did the trick.
 
Does anyone have any suggestions as what to try next? What are the chances of there being a fault with the ecu itself? I called up a place that specialises in ecu repairs and they said that they would take my money, but they doubt they would be able to help me due to the lack of information available on the car.

Needs some good thorough diagnostic checks...fuel pressure and oscilloscope logging carefully selected voltages and signals to either prove or disprove correct operation of sensors and circuits. Sounds like it's been thrown in the too hard basket by the local guys. It would probably be cheaper to ship it down to me for a week or two!!! These things arent built on rocket science...basic principals still apply!!

Hi Phil,
 
Yeah you are probably right, to be honest I am running out of options now.
 
The blokes at Byrne Ford in Kedron admitted to me that I probably know more about what is going on with the car than they do.. which is sad as I don't know much! Worse still, the last time I got the car back from them it was pissing out fuel from the fuel line which connects to the fuel rail as they had damaged the sealing surface for the O Rings !!
 
I definitely know that the issue is with the fuel pressure dropping to absolutely nothing under load once the car warms up. I have seen the fuel pressure on the OBD personally and ford tell me it is the same story with a mechanical gauge connected.
 
The other thing is that if I turn the car off and restart it, it runs fine (ie I can drive it flat out up a hill without the same issue) for a period of time. The period the car runs ok after a restart varies in relation to how long I have been driving the car.. The warmer the car is, the less time the car will run without an issue.
 
Phil, if you fancy a holiday up to Brisbane, let me know ! As I am done with giving my hard earned money to people that are only guessing.
 
Cheers,
 
Damion

I'd first want to prove the fuel pressure issue with a guage, then look at the voltage to the pump during the faulting sequence, if voltage is still good then chase a pump/tank issue, if voltage is dropping, causing fuel pressure to drop, then use the oscilloscope to check the fuel pump controller +ve and -ve in and out as well as the duty signal from the ecu. Once you know all these facts during the faulting sequence the answer will be in front of you. It is possible that the ecu is dropping its duty output to the controller, either deliberately due to one of the fuel metering calc sensors telling it to do so, or the controller output from the ecu is playing up. If the ecu is dropping the output deliberately, you will see the duty signal reduce gradually, if the output disappears all together the transistor contolling this output in the ecu is playing up.
 
Very easy to prove the basics on this one.
1. Connect mech fuel pressure guage at rail.
2. Connect multimeter at fuel pump.
3. Drive the car and produce fault, note the fuel pressure and voltage at the pump during fault.
4. Does fuel pressure drop? yes. Does voltage at pump drop? yes...test controller/ecu output circuits. no...look for fuel pressure loss at tank fuel pump module.
 
Do these tests, let me know the results and we will go from there. Sounds like your dealer doesnt have much talent in the workshop as this is really basic stuff for a good modern technician.
Cheers,
Phil.

If the fuel pressure at the rail isnt dropping, then we go down another path, although this is highly unlikely so will save confusing things with this other possibile process for now;)

Oh...and dont trust the OBD data when diagnosing these type off issues, as it is possible to be spitting out the targetted signal rather than the actual signal. This issue can arrise if a output controller in the ecu is playing up, and also depends on where the ecu manufacturer has elected to deliver the data from...either befor or after the output controller device, whether it be a transistor, var resistor, etc.
 
Only trust OBD data if you know it is correct through your own independent readings with an oscilloscope.

Cam or crank sensor?

Hi Mickas, I am not ruling anything out... but I am fairly certain it is a fuel system issue. When I have had issues with crank angles sensors in the past it has caused the car to cut out. This issue is as if the car is not upping the fuel pressure from the base line idle fuel pressure.
 
Hi Phil, cheers for all of the information. I have ordered a pressure gauge, so hopefully it will come later in the week. I will try some tests with the multi-meter this week and let you know how I go.
 
I was trying to remove the ECU, but unfortunately there seems to be a child-proof bolt preventing me from removing it.. I might have to drill it out.
 
Thanks,
 
Damion
 
 

It seems like your stuck on a fuel pressure issue...
Cam and crank sensor issues do cut out but also can produce missfires...
Check all your powers and grounds as a preliminary check over...
Also coil packs can do the same...
If your hard set on a fuel problem stick another fuel pump on it and hard wire it to the battery...almost sounds like a fuel vapour issue....
Keep us imformed...
FYI if it was a HOLDEN I would have fixed it by now

If it was a Holden, I would have burnt it by now