1.4 Tdi Struggling to start..

That I could not say, could be injector wear causing excessive foaming of the fuel or indeed a normal function for the return line due to the fuel being hotter and the possible action of the solenoid valve dumping pressure up to 2000 Bar into the port.

Perhaps even a remap could influence the return fuel.
Okay thanks :)
 
To have air in the return, when there is no air in the supply line, can only mean, (imo), air is getting in after the supply line joins the pump inlet.
Fuel after the actual pump, even within the pump body, is under pressure, and, (very), unlikely to vapourise, and form bubbles. But if it did, the bubbles are fuel vapour not air. Vapourised fuel would not get to the return line.
If their was a leak on the pressure side of the system, fuel would be leaking out. If that leak was within the injectors, then the leak would be into the combustion chamber, mixture too rich, smoke, etc.
If there was a leak anywhere else on the pressure side, air still cannot be drawn in while it's under pressure, (anything more than atmospheric). If pressure drops to zero, air can get in, but fuel must come out to make room for it, so it'd be visible.

We can see air in the return line, so there is a leak, which is allowing air to be drawn in. The leak is likely to be, (almost certainly imo), in the suction side of the pump.

Mac.
 
I took the injectors out of my spare engine today, so I thought looking at them and where they go in the engine, might shed some light on how/if bad injector seals could let air into the fuel flow?

The hole near the top must be where fuel goes into the injector
IMG_20240423_190057_HDR.jpg
In the head there are two holes, so I'm guessing one flow and one return.
IMG_20240423_185941_HDR.jpgIMG_20240423_190006_HDR.jpg
I suppose if that top O ring wasn't perfectly sealed then air could get in there?
 
Today I put the old pump back on with a new gasket (of course), bled everything through, and managed to get her started eventually, but she wasn't happy. As soon as the engine is stopped you can see air getting into the system from somewhere. I think I am done with this wee car, if anything I seem to be making the problem worse :confused:

I will put her in the classifieds and see if anyone wants to take her on..
 
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