With the leak off leak fixed and just the foaming coming down the return line I carried out extensive road testing without any starting/running problems. The customer has had the car back for 1500miles now without any problems.
Chats with mates in the trade confirmed they also had seen air in the fuel in these Ford TDCI systems without being able to find out why.
So after spending a ridiculous amount of time trying to work out why the foaming appears, I concluded that I was trying to fix something that maybe was'nt broken, and thats just the way it is?
Thanks for looking anyway.
Colin
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