Hi

Ford Mondeo non runner, changed injectors and runs fine until test drive and car stalls out and will not re-start.Check injectors they are blocked with swarf. Clean these,remove tank and flush out lines etc etc.Remove and strip pump,no signs of wear.Rebuild and car runs fine. Dont get chance to test drive for a few days but runs ok and moved around the yard daily.Decide to get the tank topped up and after driving for around 1-2 miles stalls out and won't re-start.

Recover back to garage, no codes but same symptoms.Remove injectors again, clean, refit car runs ok. New filter again etc decide to add plenty of diesel to dilute any remaining swarf in fuel.Car runs fine for a day or two,now reluctant to test drive! in case it fails again.Notice it's smoking a little on tick over revs through ok but fuel pressure is between 30000kpa put 55000kpa which seems a bit high but not sure without checking data. Still no codes.Smoking is getting worse and heavy diesel knocking intermittently. Stop motor and leave it as other work puts it on a back burner for a while. Go to start to move into workshop a few hours later and no start! iI am sure it's same fault. My question is where is this swarf coming from? the pump was fine when stripped down and whole system flushed and fresh fuel added. Is the fuel pressure far too high?Not sure that it may be the pressure regulator is at fault.
All advice appreciated.

Colin