HERES MY PROBLEM

I`VE JUST FITTED A 2.5 TD INTO MY SERIES 2 IT STARTS AND STOPS FINE NOW I`VE SORTTED THE BRAKES OUT
BUT NOW ITS CUTTING OUT ON ME.
OWNCE STARTED AND WARMED UP I PULL OFF IN FIRST AND REV IT TO ABOUT 4500 RPM THEN THE SAME IN SECOUND TO ABOUT 4500 RPM THEN IN THIRD ITS STRUGLES TO GET TO ABOUT 3800 RPM AND THEN IN FOURTH IT STRUGLES TO GET TO ABOUT 3200 RPM THEN CUTS OUT (JUST GUESING THE RPM`S).
STARTS UP OK THEN IT ALL HAPPENS AGAIN SOME TIMES FURTHER DOWN THE GEARS AND REV RANGE.
ALL HELP WELCOME.
THE ONLY THING I CAN THINK I`VE DONE WRONG IS THE FUEL LINES AND IF ANYONE CAN POST A DIAGRAM OF FUEL SYSTEM IT WILL BE A BIG HELP.
THANKS ADAM

Sounds like a fuel starvation problem, possibly a pump problem or clogged filter/line.

I don't have a diagram I can post, but simply put, you should have a pipe from the tank to the lift pump, lift pump to filter assy, filter assy to injection pump, spill pipe from IP to filter assy, filter assy to tank spill pipe and the injectors will have a spill either Tee'd into the tank return or into the filter assy, and of course 4 injector pipes.

But for now, all we will worry about is that the engine is getting fuel.

So, first off, I would check the lift pump, uncouple the lift pump OUT pipe, and give it a few pumps by hand, if nothing, turn the engine over a 1/2 turn either by hand or on the starter (do this when its cold, might start if hot). Then try the lift pump again, if it still does not pump, then you have a dodgey lift pump, so basicly the injection pump is doing the work of the lift pump aswell, but struggling and eventully cutting out through lack of fuel. Had this with my 300tdi recently.

If the lift pump works, then I would have a look at the filter, is it new? Could the filter have been choked up with gunk if you have disturbed the tank while fitting lines etc?

If this all checks out, with the engine running undo the bleed nipple on the IP a bit and make sure there is a good steady flow of diesel coming to it. If so then the injection pump could be the issue and need overhauled.

What sort of fuel lines did you use? Could they be collapsing when the fuel is being sucked through, you will not be able to see this by revving the engine as the fuel demand is not high enough, so be sure your fuel lines are designed for the suction side of a fuel system.

On the engine speed thing, I think that 4500 is a bit high before changing gears, these engines like to work hard and stay at low speeds.

Is it drawing in air from somewhere on the fuel lines?