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Old 11-03-2012, 07:14 PM   #17
Focus Jr. Enthusiast
Join Date: Feb 2006
Fan#: 32067
Location: australia
What I Drive: 2003 silver 2.0. zetec

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Hey Everyone,

So I have completed a whole series of checks as follows:

- Reverted ECU to stock tune. Car still started up and stalled.

- Tested if connecting the vacuum hose from the fuel pressure regulator to the intake manifold or the casting that the TB connects to would make in difference. The car behaved exactly the same irrespective of where the vacuum hose was connected. Would start up and stall.

- Disconnected vacuum hose from fuel pressure regulator altogether. Started the car up and it behaved exactly the same as when it had the vacuum line connected to it. This makes me think I may have broken the regulator?

- Tested whether blocking off the fuel pressure return line would make the car run. Again this had no effect. The car started up and again stalled. There was definetely fuel pressure there as the multigrip I was using to block the hose I connected on slipped and I got a huge spray of fuel out of the hose.

Other things which I did in an effort to trouble shoot the problem:

- Removed the IAC and cleaned it out with carby cleaner and reinstalled.

- Removed the supercharger and intake manifold to ensure everything was seated properly and that the vacuum barbs/ports were clear (I was going a bit crazy at this stage when I committed to this). One thing to note was there was a reasonable amount of fuel sitting in the intake manifold. Enough that I thought it smart to wipe it up with a microfibre cloth. Say 20-30 ml of fuel.

- Checked all connections, grounds, fuses.

After doing all of the above I still have had no luck getting the car to run.

My questions are as follows:

- If the car is behaving the same whether the fuel pressure regulator has a vacuum line connected or not, is this an indication that the regulator is broken?

- Would a broken fuel pressure regulator cause the problems I am having? ie. car starts up happily and stalls.

- Could my problem be related to poor injector positioning/mounting? I ask this as I found some fuel in the intake manifold and wondered if they weren't directed at the intake ports correctly? The injectors on the car now are a brand new set of 42 lb bosch injectors. Would it be worth throwing the stock or a set of 38 lb injectors on there to check it isn't a problem with the new injectors?

- Could the car be flooding? ie. its just getting too much fuel? I would have thought reverting to the stock tune would have stopped the flooding if it was the tune providing too much fuel.

- Could my problem be the inertia fuel switch? I used this when installing the kit to deplete fuel pressure in the lines. If it was constantly activated would it allow the system to pressurise in the first instance?

The only wiring/harness that I have messed with are the MAF and knock sensor. I had to extend the Knock Sensor wire to fit around the intake manifold and I have relocated the IAT sensor to the intake manifold so I have cut the wires to pins 1 and 6 of the MAF to connect the relocated IAT sensor to. Could either of these be the source of my problems?

The car hasn't thrown any codes at this stage and I've tried to start it up at least 15 times.

Final thing to note. I advised incorrectly in an earlier post. The datalogging I completed prior to installing the JRSC kit did not show any fuel pressure either. So I think the datalogging file Tom has provided on the ECU forum is applicable for an Australian delivered focus for fuel pressure.

Sorry this is such a long post. Just trying to put all my information out there. As I have said previously I am very keen to get this fixed.

Thanks again,

mj22 is offline  
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