I'm not sure what sort of fuel injection pump you have being a later engine but the earlier ones have a couple of electrical connections to them, one is a cold start advance feed, if this wire is disconnected or has no voltage, it will give the symptoms you have. As I said I am not sure that this is the pump you have but if it is you can check the operation of the pump by applying 12 volts to the lead coming from the pump.

hey guys,

Thanks for the very useful information so far..and aplogies for the delayed reply (12hour days and no tinkering time!!)

So last night when i got home, I opened the bonnet while the engine was running, she had only cut out on me once on the way home. So i was looking for the black valve you mentioned, think its a non return valve? Any how..when i moved and disturbed the pipe (between the output of the fuel filter to the pump) the engine started to cough and splutter, then just cut out...i was happy with this...a starting point !!

So this morning i removed the black pipe and replaced it with a clear pipe...Can now see the problem, think the primer is leaking air, as there is looooooooads of air bubbles in the line, and when it stalls, there is no fuel coming out of the fuel filter, hence starving the engine.

Or does this point to the fuel pump not sucking hard enough? Not to sure if there is a pump connected to the sender unit in the tank?? Please bear in mind i still have a leak somewhere near the fuel tank i need to sort, which im guessing isnt helping matters, and might even be the cause??

Thanks for all your help so far, ill let ya know what happens :-)

Joff

There is no pump in the sender unit-this system relies on fuel being sucked thro' by the injection pump.Hence the reason air enters the system at the slightest leak.

Edited by jc2 on 25/11/2010 at 14:50

been having the same problems with n reg escort van. in the morning she will start and rev, then die which results in much engine turning over until she fires up again, then when driving sudden loss of power in any gear and lumpy running particularly at low to half throttle. the garage said this was due to a leak in the fuel return line and suggested a non return valve.i pointed out that this would only solve the morning starting difficulties. so we replaced the lift pump. no joy. so as a last gasp effort i dropped the fuel tank, lo and behold the out take pipe on the fuel sender unit was full of corrosion and holes. checked inside the tank as far as i could with a mirror and torch, no holes despite the rust on the outside. ford wanted £70 for a sender unit f*** that, found one at kitspares.co.uk listed as a sierra fuel sender, £20. fitted, working, problem solved. you would not believe the corrosion on top of the fuel tank, still nothing new there from a ford!!!!!!