HAHA, If it was a Holden I would have burnt it too, not that I am ruling that out for the focus yet.. But at least I would have been able to buy another commodore for $250 and be on my way again !
 
Ok, so had a bit of a fiddle tonight..
 
Found a table giving me reference voltages to fuel pressures at the fuel rail pressure Sensor (FRP)

http://www.feoa.net/modules.php?name=Forums&file=viewtopic&t=71016



I put a multi-meter across the vref and the signal return wire on the fuel rail pressure sensor and I got 3.62V at idle, once driving the car and putting it under load the Voltage drops and thus the fuel pressure drops, nothing new I know (Will get a  mech gauge on there eventually to confirm.. But ford have verified this, so hopefully they have done one decent thing for the $$$$ i have given them).
 
I bridged the vref and the signal return and there was no change, I also tried removing the vac hose and there was no difference. So at least a vacuum issue and the FRP sensor should be ruled out once and for all.
 
I also checked the 5v 'frp signal' wire and it remained at a pretty well constant 4.9v under all conditions.

I have to remove the 'special' bolt preventing me from removing the harness plug off of the ecu so I can find the vref wire going into the ecu. I am thinking that I will bridge this wire between the sensor and the ecu and I will also ground the signal return to a good ground, hopefully this will rule out a wiring issue.

I can't seem to remove the bolt holding the ECU harness cover on,I think I am going to have to grind it off.

I will also try to check what is going on to the pump in the next couple of days. I don't know if the multimeter will tell me much.. but I guess if the readings don't change when I put my foot down the issue is upstream of the pump, if there is a change noted I should be looking at the pump (Like you said Phil). I have changed the pump twice so the likeliness of an issue in there is hopefully next to nothing.

Cheers.

Cheers.

Hey Ty,
 
Yeah apparently coil packs are a common issue on those things.
 
It is definitely a fuel pressure issue on my car. I got home this afternoon and connected up a mechanical fuel gauge and a multimeter to the +ve and negative wires that go to the fuel pump. But unfortunately the car seemed to be running ok today.
 
the multimeter was reading constant voltages from about 6v to 12v when I was under the hammer, the fuel pressures seemed a little low between 30 and 40 psi. I will take the car for a better drive tomorrow night if I get home at a reasonable hour.

Hi Phil,
 
If the Fuel rail pressure sensor is telling me the truth (which I believe is likely at this point) fuel pressures drop down to 0 if I stay on it, at which point the car cuts out. This was from the tests I was doing prior to having the mechanical gauge on there.
 
I just cut into a power source at the rear of the centre console and connected it straight to the fuel pump and bam! there was an instant 60+ PSI to the fuel rail and the multimeter was only reading 10. something volts, whereas yesterday it was reading 11.5 odd volts and only seeing 30psi or less when I was under it, but I guess that must not be a constant voltage and my multimeter is not quick enough to pick up the cycling on and off of the pump?
 
At least I know the pump is capable of producing that sort of pressure now. And the fuel pressure is holding constant pressure at the rail once the power is off at the pump, so that should rule out any issues downstream of the fuel rail.
 
Hopefully I am narrowing down now.

Hi joeyjonsey,
 
Just the factory alarm.
 
Cheers.

Hi Pete,
 
Not that I am aware of, the exhaust system runs down the passenger side of the car and the fuel lines run down the drivers side.
 
I will jack the car up and have a good look on Saturday.

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

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.

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.