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Originally Posted by DieselScout
I installed clear tubing on my injector return lines the other day.
All lines have lots of foaming/bubbles going back to the "out" port on the injection pump. Is this normal?
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It is normal for a few persistent bubbles to remain at the tops of the return tube arcs. Constantly forming small bubbles not so much. Where is that coming from?
The main problem with leaks in the fuel return tubing is that when the car is parked pointing uphill overnight, air can enter at a high point and allow fuel to drain out the IP back into the tank. Results in hard starting when the IP is full of air. I have had this problem with a leaky end cap on the #1 injector spill port and another time with a leaky fuel return tube at the IP out port.
A good troubleshooting method for you would be to splice in a low pressure (3-5 PSI) fuel pump before the fuel filter inlet. See if this changes your issues.
Quote:
Originally Posted by DieselScout
I've rebuilt a few injector sets, all having some effect on this to a degree, but never getting rid of it entirely.
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How close did you get them? Did you ensure no drips/moisture at the nozzle pintle when held for 10 seconds at just under POP?
Quote:
Originally Posted by DieselScout
I've checked the copper rings between the banjo bolts and inspected for fuel leaks. All appear to be stable
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Air can enter much easier than fuel can leak out.
Quote:
Originally Posted by DieselScout
Injectors are freshly rebuilt (DN0SD193 style) and set to 2000psi.
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Not familiar with that style.
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Originally Posted by DieselScout
I think oil consumption is about 1 quart every 2,600 miles, but need more time to verify that metric.
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Most excellent!
Quote:
Originally Posted by DieselScout
Again, the car drives fine for all intents and purposes, but I just want to make sure it's 100% before I take this on a cross country trip to the higher elevations of Montana/Wyoming.
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Take extra fuel filters and make sure your cooling system is in top condition. Hill climbing at high altitudes will stress it to the max. No cheating allowed there.