Hi, Ford Focus 2008 1.6 TDCI no power, only revs to 2000 rpm out of gear and smokey, no fault codes, no knocks, engine actually seems very smooth, doesn't seem to be any air leaks, had some spare parts off a known running engine, tried replacing EGR valve and throttle body, Turbo is spinning at both sides of the shaft and actuator seems to be working fine, fuel filter replaced, have run fuel from a Jerry can, to eliminate any fuel supply problem and problem with the fuel itself, MAF sensor replaced. Tried disconnecting exhaust to eliminate possible DPF blockage. have monitored data using forscan whilst running and Throttle pedal sensor seems fine. Another point to note is it has had brief moments of coming back to life and reving freely again which suggests to me that it can't be a belt slip leading to the fuel pump being out of whack.
My best guess is it's a fuel to air ratio problem but after trying all the above I just don't know what else to try, given how smooth engine is I can't see it being a problem with injectors? I'm a mechanic by trade but classic cars so not a specialist on diesel engines, one thing I found strange is there are two electrical connections on the throttle body that control some Air Flow flaps, with the wires disconnected this doesn't seem to alter the running at all is this normal? could it possibly be an ECU problem where maybe it's not sending signal to open these valves?
Looking at the live running data from Forscan I can't see anything obvious but maybe someone with better experience of what some numbers should be might be able to see something that would give some clues?
I'm pulling my hair out on this one any help very much appreciated, thanks.

The throttle body valve doesn't really move during normal running.  It closes off the intake at switch-off to prevent 'shudder' on shut down.  And it partially closes when the EGR opens to ensure that intake air is being dragged from the EGR instead of the outside.

The high-pressure pump isn't timed on common rail engines.  It's purely there to provide pressure in the rail.  Has no effect on injection timing like the old mechanical diesel pumps did.

I'm guessing it's a 110ps model as you mentioned DPF...  So sticky turbo vanes would definitely be something to look into.  Check the boost solenoid is actually operating and the vac hose isn't split.  No mention of MAP sensor, so that could be worth a check - comparing MAF against MAP is a good indicator of whether there may be any boost leaks.  The solid metal boost pipe is common for snapping around the brackets, even a tiny hairline crack here will lose enough boost to confuse the MAP sensor and pull back the fuelling.

thanks for your reply Tom, the throttle body valve explanation was most helpful so seems there's no reason to expect a problem with that, pretty sure there is nothing wrong with the turbo, has been the thing I've checked the most as certainly would fit with the fault but it is perfectly free, spins as it should both sides and no play, actuator working so seemingly no problem with the vacuum lines, I've not looked at the car for a number of weeks, from memory MAP sensor is fitted on the throttle body have swapped the MAP sensor and indeed the whole throttle body. have checked the metal pipe and indeed all the other hoses quite intensively for any cracks/splits/leaks all seem good though maybe you could elaborate on 'comparing MAF against MAP results'? if one could conclude from this that there is a boost leak wouldn't this throw up an error code? when I first put forscan on there was some codes but seems historic as they are not returning now.

If you run the live data graphs on Forscan with MAF and MAP together, you should see the MAP curve follow the MAF curve fairly closely.  (Makes sense, the more air you pull through the MAF, the more should be appearing at the MAP, unless there's a boost leak in between the two).

On the 110ps model, there is a second throttle valve which acts as an intercooler bypass.  (When cold, the intercooler is bypassed for a quicker warmup).  I can't remember which valve the MAP is on now but if you've definitely swapped it then that can probably be ruled out.

Forscan is usually best for fault codes on these so it does seem odd you're not getting any.  I would expect an underboost code if there were any boost leaks or stuck turbo vanes.  It's difficult to know what to suggest next with no codes after extensive practical checks.

Faulty glowplugs can cause limp mode on these - but that should flag the 'engine malfunction' message on the dash.  Same goes for an empty Eolys fluid tank.

I still wouldn't rule out injectors yet.  I take it you don't have any work connections that can bench test the injectors for a decent price?

I'll have another check at the live data regarding the MAF and MAP numbers, there is indeed two valves on the throttle body, I swapped the engine 10,000 miles ago have the injectors off the old engine, think if the numbers on the MAF/MAP seem okay replacing the injectors will reluctantly be my next step I think.

For reference the MAP at Idle should be Atmospheric pressure, 100 kPa, and max out at around 240 kPa under high load with the car running.

I would expect the MAF to be around 6 or 7 g/s at Idle.

I would also monitor the Fuel Rail Pressure as well, and preferably monitor everything with the car moving and also include Speed, RPM and Accelerator Pedal position for reference when you are looking at the data later.

There should also be some PID's in FORScan for the Turbo, I can't remember what ones are there or how useful they will be.

brilliant thanks for the info, today didn't go as planned so still waiting to get the data to look at, hopefully know more tomorrow