Took another look at the delivery valves last night and when I took the valves out all 5 cavities below the valves were empty. (when I did this before they stayed filled with diesel) That means the fuel had drained back into the pump and that also explains the starting issue. Starts up fine with the fuel still being in the line between the valve and the injectors and when that is used the rough idle and nailing starts until the pump somewhat catches up. Also explains the nailing due to air getting into the system, or am I wrong here? Does that sound like an air leak and if so what would be a good way to troubleshoot that.

..Udo

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1991 300D 2.5 Turbo (185000 miles)
2002 BMW 330 cic (65000 miles)
2000 Vulcan Classic 1500 (47000 miles)