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    Posted by Sean Mc Gettigan on February 15, 2004, 10:30 am, in reply to "Re: FORD MONDEO V reg 2.0 16v ZETEC"

    Thanks for the replies lads.Went in yesterday morn and started with a fuel flow check, 1.5lts/min so no problem there.Started from the begining again and found the engine was now running weak!All the live data was the same except the inj duration was now 5.2ms.Compared the data to prev days readings and nothing made any sense so I pulled the fuel rail and bingo .It looked like the pintle caps were partially melted on each injector, a complete mess.Ran them on the ANSU bench for a laugh and they were all crap!
    Left the job then and carried on with other work as it appeared to need injectors. Later in the day curiosity got the better of me and I dropped one into the cleaning bath.Returned a few mins later and the melted cap was dissolving! It appeared to be some sort of corrosion/errosion build up!I looked into the inj ports and the same crap was built up on the back of the cylinder head which scrapped off easily.Ran all the inj through the cleaning process and retested, all perfect and the flow about doubled.Stuck it back together and ran the engine before I left for the night and once started and cleared the engine idled and reved up fine.
    I'm thinking contaminated fuel and the car has been sitting up for a while.The owner(new cust) says he just bought the car and has a warrenty. Anyone seen this before or got any other ideas of the cause?
    I'll take data readings off it tomorrow and post for future referance as it appears all the info I got from Fords tech helpline is incorrect (including a four wire wiring dia for a six wire AMM which can only be tested on a laptop in a Ford dealer).
    Iain wheres the engine code and I'll post that too, I could'nt see it to post prev?
    Thanks Sean

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