I have replaced the copper injector seals because one was leaking.

Replaced all copper seals new stretch bolts on injector forks

No fault codes on FORScan

Fuel pressure 30,000 kPa

Bled the fuel lines, still some bubbles coming out of return line (manual rubber bulb and electric  vacuum pump used)

No leaking spill return pipes

Will start on easy start but not diesel

I'm now stood with insurance policy in hand and box of matches contemplating committing a minor  technical infringement to rectify situation

Any one have a clue as to what is wrong, i suspect an air blockage but I cant get it to run clear on return

HELP!  

 

There is undoubtedly an air leak somewhere in the fuel system. Have you changed the diesel filter ?

Filter changed, new seal.... 

If you've got 300bar of rail pressure it's not a physical fuel issue.

Dud the injectors go back in the same cylinders?

Injectors all put back in correct place, labelled and double checked. It did run once for 30 seconds but no accelerator just ticking over. Now nothing..

Throttle position sensor is indicated as moving on FORScan

All injectors getting pulse signal from PCM, tested with Noid light

High pressure fuel sensor replaced from known working engine. No start

 

 

Very odd there aren't any fault codes on Forscan.  If you've got good rail pressure and injector pulses, the fuel should be reaching the cylinders.  If some injectors have emptied, they should self-bleed by purging air while the engine is being cranked, there's nothing you can do to bleed those except keep cranking.

Maybe try deleting the car from Forscan so it's forced to set up a new profile and do a full scan again.

Did you have to unplug anything other than the injectors that may have been forgotten during the refit?  Cam sensor etc?

High pressure fuel sensor on fuel rail, replaced but both sensors ok. Fuel pressure all to spec.... I'm gonna try and bleed the system again feeding into pump with pressure and vacuum on return. I'm sure it's a blockage of air...