I have a can clip and found that the rail pressure was taking some time to build up when cranking on start (the battery is in good condition) but when it eventually started the rail pressure at tickover averaged around 280 bar.
I removed the pressure limiting valve from the right hand end of the fuel rail, carefully seperated the valve end from its main body, as I could not see anything obvious inside the valve I blew it out, reassembled and refitted it to the rail. At this time I checked inside the filter casing again and found a substantial sediment deposit along with a small amount of what I presume to be the dreaded swarf ( it looks like gold coloured dust which is highlighted by directing the beam of a small handlamp at it). There was nothing on the paper filter element. Reassembled it all and reprimed and vented the fuel system using the electric priming pump and cracking open the rail union on the hp feed from the main fuel pump. After this the engine started first flick of the key every time for about one and a half days.
It then became difficult to start again, found some more of the sparkly stuff in the filter housing, gave the pressure limiting valve a tap with a small hammer it started fine again.
My suspicion is that the fuel pump is lunching itself and swarf particles are becoming trapped in the seat of the pressure limiting valve allowing fuel to leak away from the rail causing the failliure to build rail pressure quickly at start up. My main question is how long has the fuel pump got before it fails ccompletely and can any one confirm that the sparkly dust is the dreaded swarf.
Thanks
mervynd
Currently in mervynd's garage:
2003 Trafic ll29dci100,2001 vw Golf sdi,1976 Triumph stag
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Trafic 1.9 dci 100 poor starting / swarf in fuel filter
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