Possibly similar issue in brother-in-law's Transit back in the 90's.
Driver would switch off to make a bread delivery, then flatten the battery trying to start it, then ring me at the crack of dawn.
Nipped up the joints on injectors, pump, checked lift pump, filters etc. like you would.
Not a sniff of a leak anywhere, nothing wet.
So not leaking fuel out but still seemed like it must be leaking air in somewhere while the engine was stopped.
Nothing too complicated about old vans.
Could see that the plastic feed pipe from the tank ran up the firewall to some kind of joint up high on the passenger side.
Sort of worked out/guessed that gravity might be happening and phoned a specialist who confirmed my guess-theory with a laugh and told me about the stupid tenpenny o-ring in that joint.
Weight of fuel in the vertical part of the pipe below the joint was all it took for it suck air in.
I reckon someone probably had re-used the o-ring and that had caused kind of a flap or a crease to form - and that was acting like a one-way valve.
I swear there had been no trace of leaking diesel at that joint - but replacing the o-ring fixed the problem for good.
Transit 190, 2.5d I think it was. Edit: 2.5di was it?
Hope you find whatever it turns out to be
