I suspect the problem is in the return line or in the feed/return/sender unit inside the tank. I'm anxious that this could cause knock-on damage, not least because of the wear on the starter motor. I still have the problem that the fuel gauge will randomly drop to reserve before gradully creeping back up (although otherwise, once started, it runs beautifully). It still takes a while to crank AND today when it finally started there was a violent vibration before the engine settled down to normal idle. The manual pump and NRV are definitely the right way round.
I put a small rubber bulb-type manual pump in the feed line (the pump has a non-return valve in it), and I noticed that when I operate the pump I can hear air bubbling up inside the tank presumably from the return line which comes from between the fuel pre-filter and the fuel filter. CityWest Commercials told me the fuel was draining back, that it could be an extremely small air leak in the low pressure feed which could be very hard to find and that I could try installing a non-return valve to narrow down the section where air was getting in. The fuel gauge would suddenly show reserve even if there was fuel in the tank and it would take probably 10 to 20 seconds cranking before it would start. It seemingly began when I was parked on any sort of incline, altho that could be a red herring. Hi all, I have a worsening fuel delivery problem when starting (OM904L engine).
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