WL2.5 TD Sick and Running rough

[tommyb43]

Hi folks been on the side for a long time
My Bongo has broken me with a rough running engine.
Story is i rebuilt Sadie from the ground up,
New top end with the usual bits cambelt water pump and so on
Full welding package.
Running sweet as a nut for 3 weeks never missed a beat, On my way to work one morning Limp Mode
is the only way i can describe it as i know they dont have it.
Flat no power NO Smoke No warning Lights just flat.
Starts first flick of the key no grinding nothing and runs flat sounds like fuel starvation or air leak.
New Injectors New return rail New Fuel filter, Blow fuel back to the tank clean no blockages.
Cracked all the injector pipes at the injectors and the pump Loads of fuel coming through.
Disconnect vacuum pipes and engine revs drop. Swapped vacuum valves no difference.
I am out of suggestions and cant think of anything else to look at.
Questions please and suggestions Sadie has Broken me and i am lost.
I am a timed served mechanic but not Diesel mechanic.
Please help

[g8dhe]

Have you checked the fuel filter and the small banjo filter ? Does it rev up to below turbo speed and then go flat ? Might be turbo ?

[tommyb43]

Thanks g8dhe New filter and banjo bolt filter new Engine revs but lumpy Turbo is fine Revved flat out and insecure clip on the inlet pipe blew off with a pop so good pressure.

[g8dhe]

Is the Glowplug light coming on with the ignition ?
If its not then that might be hiding a fault code as if it flashes it indicates that there is a diagnostic code stored ready to be read out ...

[teenmal]

Check the timing .

[tommyb43]

Is the Glowplug light coming on with the ignition ?
If its not then that might be hiding a fault code as if it flashes it indicates that there is a diagnostic code stored ready to be read out ...

No lights glow plug light on for a few seconds and goes out ! I tried to flick the starter to turn the crank checking timing marks, which was imposable because the engine fired every time within half a second never fails to start but runs lumpy on idle like its off a cylinder. and no power at all will not reverse up a slight incline.

[teenmal]

Is the Glowplug light coming on with the ignition ?
If its not then that might be hiding a fault code as if it flashes it indicates that there is a diagnostic code stored ready to be read out ...

No lights glow plug light on for a few seconds and goes out ! I tried to flick the starter to turn the crank checking timing marks, which was imposable because the engine fired every time within half a second never fails to start but runs lumpy on idle like its off a cylinder. and no power at all will not reverse up a slight incline.

Turn the crankshaft/ flywheel manually, it not too hard to do.

[tommyb43]

Checked teenmal Timing Bang on Belt has not slipper
Compression is Very good needed a longer bar to turn the crank with 38mm socket

[tommyb43]

UPDATE
Removed and replaces banjo bolt copper washers checked with a still tank on inlet pipe to eliminate fuel filter, Still Rough.
Checked return pipe into a still tank air bubbles on returning fuel ? Must be an internal air leak into the system NO External Leaks.
Pump is clean and dry on the outside NO Leaking Fuel Any ware Must be drawing in air form some of the seals internally..
Any recommendations as to what can draw air into the system ?

[davetheshrew]

check the rubber fuel return pipe behind the intake manifold, had to replace mine last week seemed to help a bit. put your hand under the fuel pump and check for fuel also seals might need doing. pump timing could be out also.