Sorted!! Unbolted the cat at the turbo and it revved no problem so bolted it back on and unbolted it behind the cat and struggled to rev and reeked like mad so the cat is to blame..
I removed it and cut the cat open at each end exposing what was left of a quarter of a melted, black, blocked cat, which I removed and seam welded the exhaust back together refitted the exhaust and hey presto it starts, revs and theres no black reek at all.

It's obviously had faults prior to this weather it be the egr valve, the injector wiring loom or even the fuel pressure regulator that looks like its a recent part and caused the cat to get choked up. Iam just glad it fixed now. Dont know who is more pleased me or the guy who's it is lol.
 
Sorted!! Unbolted the cat at the turbo and it revved no problem so bolted it back on and unbolted it behind the cat and struggled to rev and reeked like mad so the cat is to blame..
I removed it and cut the cat open at each end exposing what was left of a quarter of a melted, black, blocked cat, which I removed and seam welded the exhaust back together refitted the exhaust and hey presto it starts, revs and theres no black reek at all.

It's obviously had faults prior to this weather it be the egr valve, the injector wiring loom or even the fuel pressure regulator that looks like its a recent part and caused the cat to get choked up. Iam just glad it fixed now. Dont know who is more pleased me or the guy who's it is lol.

Nice find.:)
 
I had the exact same symptoms with my 2005 Defender 110 Td5. The problem for me turned out to be air intake hose. The main hose (the large one) that brings air in was delaminated. The different layers of the rubber were separated and the inside of the tube was collapsing under demand. The hose was closing up inside and choking off the air intake. This was hard to find because the outside of the hose stayed in its regular shape.

This also didn't give any helpful error codes on the computer.

Hopefully this helps if someone else runs into something similar.
 

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