Hi, thanks for reply.

ECU was coded with opcom.

My fuel pressure tester connection doesn't fit the schrader valve on the fuel rail so removed fuel rail/ injectors and connected back up on top of engine to confirm injectors were spraying fuel. All good. Not sure if they under/over deliver fuel though due to the fact I can't connect the pressure tester.

Any thoughts on how to test the fuel pressure? I was going to remove the fuel inlet hose from the rail to connect but the lower end of this hose has a permanent connection so that's no good.

Attempted to remove the lamda sensor but couldn't as it looks like you need a deep socket (which I don't have!) and there isn't room to get standard spanner on. Again any thoughts?

Appreciate your help.

Thanks elekie&a/c doctor and railroad. Your replies have made me to look at the exhaust as a possible cause of the crank no start which I hadn't really considered before.

Today I removed the exhaust manifold (includes the cat) to access the lambda sensor and check for blockages etc. The manifold is clear, obviously has carbon build up but all clear. On inspection the bottom of the cat looked fine but after removing the top lambda sensor I could see that the top part of the cat mesh has some damage - a roughly 25mm crater in the centre. Not a hole but a 5-10mm deep indent. Could this mean that the cat is damaged/blocked and causing the no start? Is there a way to test a cat? I don't want to keep throwing money at the van unless it's highly probable that this is the problem.

Thanks in advance.

Thanks elekie&a/c doctor and railroad. Your replies have made me to look at the exhaust as a possible cause of the crank no start which I hadn't really considered before.

Today I removed the exhaust manifold (includes the cat) to access the lambda sensor and check for blockages etc. The manifold is clear, obviously has carbon build up but all clear. On inspection the bottom of the cat looked fine but after removing the top lambda sensor I could see that the top part of the cat mesh has some damage - a roughly 25mm crater in the centre. Not a hole but a 5-10mm deep indent. Could this mean that the cat is damaged/blocked and causing the no start? Is there a way to test a cat? I don't want to keep throwing money at the van unless it's highly probable that this is the problem.

Thanks in advance.

Thanks elekie&a/c doctor. Good point.

No I haven't tried to start it with the exhaust off - I damaged one of the fuel injector top o rings when refitting the injectors so I definitely need to replace this before starting her up or the fuel and possible flame mix could be the end of the van and me!!

I will order the o ring and once I have the fuel rail back in I will see if it will start with the exhaust off. This will prove either the cat or exhaust system is the problem or that the problem lies elsewhere.

i will clean and test the lambda sensor tomorrow.

Your help is very much appreciated.

Ok thanks.

If the lambda sensor shows any reading on opcom does this prove that the sensor is fully working and therefore sending a signal to correct the air/ fuel ratio?

Thanks for the detailed explanation Railroad.

I can now cross the lambda sensor off the list!

I have now ordered a new injector o ring so, once fitted, I will attempt to start the engine with the exhaust manifold removed.

Surely it's got to be the cat/ exhaust as all the other requirements are being met - fuel, spark, compression, air.....

Assuming the engine is drawing air, the compressions are good, and the exhaust is clear. If you're sure they all are you'll have eliminated a lot already. Make sure the spark plugs are clean and dry. If they're wet with fuel the engine could be flooding with excess fuel. If they're oil fouled you could have a lot of other problems.

Have you tried a spray of brake cleaner into the air intake? If it starts you'll know the problem is fuel. If it still doesn't then suspect an HT spark fault.

Edited by Railroad. on 18/04/2020 at 18:49