Hi Matt, 
 
Thanks for the tip. Not sure if that could cause the issue I am having, but I am running out of options now, so might be worth a try.
 
I tried another ECU in the car and it didn't change the issue. So I bit the bullet and wired the pump to an auxilary power source. I did the test after the car had been running for some time (as the issue is only when the car is hot). This saw 60psi at idle, but a similar low pressure issue occured when under load...
 
I ran another fuel line down the length of the car this morning and it ran for over an hour (much longer than normal) before an issue arose.. But an issue arose.
 
I think I have no other option other than to remove the tank again and have a good look in there. Just can't put my finger on as to why it only happens when it is hot.
 
Does anyone know what are the signs of a blocked Cat converter are ? And what would happen if I was to unplug the O2 sensor? Would the O2 sensor lean the car out if the cat was blocked? But I guess if I direct wired the pump I can rule out the O2 sensor.
 
Cheers,
 
Damion

Blocked cat, Car would be hard to start, and also it woudn't rev out. Really depends how blocked it is.
My XF used to have a sort of similair issue. Got hot loss of power and ping a bit. Sometimes when driving I would cycle the ignition adn fixed it. I eventually got the ****s and held it flat up a hit.... It then spat and popped the catalytic converter out the rear tail pipe Mine wasn;t hard to start tho...

Interesting, mine will happily rev to 7000rpm when it has fuel pressure, haha.
 
I am going to go back to square one. I have dropped the tank and I am going to put the original fuel pump back in and see how the car behaves.. If it behaves the same I can hopefully safely look elsewhere.

one more thing to try , have you looked at intake or temp sensor. just incase it is reading high temps and shutting down

Hi blackmk1cossie, the only temp sensor I can find is on the thermostat housing. I know that this sensor controls the gauge and fans, but I am not sure if it is the coolant temp sensor for the ecu. I tried disconnecting it to see what happened but no change unfortunately.

If it has a Mass Air FLow the Air temp sensor will be built into that...

Hi Ford_Escort,
 
Cheers for that.

To me it sounds like a cam sensor or crank angle sensor. When the car gets hot it looses track of the timing (causing the miss fire) then gets worse and shuts down. My father just had a similar problem with his SRI Barina. He tried everything even a new ecu, feul pump/filter, plugs, leads, coils. turned out to be the cam sensor. I'm not saying it will fix your problem but it seems you have checked and double checked the fuel side of things with no luck it might be time to try something else. An easy way to test the crank/cam sensors is when its hot and starts miss firing hop out and pour water onto the sensors to cool them down, give it a minute or so then start it up again???? Im no expert but seems your running out of options!...   hope it helps.  Mick B    

Hi Mick B,
 
Thanks for the info. As you said, I seem to be running out of options. I haven't checked the injectors yet, but I can't imagine that they could cause this issue.
 
I might price up some sensors this week and see how I go.. Unfortunately by turning the engine on and off it starts running fine again.
 
I'm not sure which sensor gives the feed to the tacho, but if there is a crank sensor and a cam sensor, my guess it would be the crank sensor? The tacho behaves fine, so maybe I will look at the cam sensor first.
 
Cheers.

hi,  i no its an old post but was wondering if you ever managed to sort the problem as im having the exactly the same issue with mine. cheers