Astra 1.7 CDTI (G) 2005 won't start

[celtJon]

EOBD software reading 0 PSI from the fuel rail pressure sensor when cranking the engine. If the connector is disconnected from the sensor, then it reads 26106 PSI which is 1800 bar (the maximum expected fuel rail pressure), so if the sensor fails that would be the signal the ECM gets. No DTCs recorded. Any suggestions?

[E-bmw]

In other words you have no fuel pressure...... It will never start without fuel.

Have you tried bleeding the fuel lines?

Does it have a pump at the fuel tank end?

Does the fuel pump start?

[celtJon]

Exactly, but is registering exactly 0 PSI with no variation which seems odd (assuming the sensor is ok). Yes, the tank is a quarter full, diesel in the return line from the pump when cranked, Suspect the pump is the culprit.
System bled. No lift pump on this model, only HP pump.

[E-bmw]

You say there is diesel in the return line when cranked, is it coming from the injector rail or from the tank?

[celtJon]

It's from the pump back to the tank (it's the return outlet on the pump body) The leak off pipes at the injectors are dry since the the rail isn't seeing any pressure and during cranking you wouldn't expect excess flow at the leak-off ports

Edited by celtJon on Monday 21st August 12:55

Edited by celtJon on Monday 21st August 13:21

[E-bmw]

Sounds like the pump is Jacobs (cream crackered) to me.

Others may have more specific experience of this car than me though.

[celtJon]

That's my suspicion. However it ran fine on Saturday before I replaced the cam cover seal which required disturbing the injector fuel pipes and leak-off pipes. I would have expected it to throw a DTC if the pump really has a problem.

[E-bmw]

Do you think it would have been a good idea to tell us that first?

I'm out of here!

[celtJon]

No. The issue does not appear to be related to the parts which were removed/replaced. This appears to be an incidental secondary problem.

Looking like an immobiliser fault (see https://www.pistonheads.com/gassing/topic.asp?t=13...

Getting the following codes with brake and accelerator both down and ignition to last position before start:

007071
210870
050074
05007F
010104
019011
161450
21397F

Edited by celtJon on Monday 21st August 15:47

Edited by celtJon on Monday 21st August 15:52

[M32Guy]

The code I'd be concentrating on is

161450 - wrong transponder key

This will prevent the engine from starting. I'm assuming you have the flashing car/spanner light on the dash when cranking? Have you opened up the key at any point prior to this fault or are now using a different/spare one?

The only other code from that list I'd be concerned about is this one

019011 - Rail pressure sensor high

but you've said you've disconnected it so that could well be why that's there.

Really need to get a dedicated scanner on and clear the faults and see which come back up as present. The pedal test will show all historic codes which can lead to wild goose chases. Generic OBD scanners are no good with Vauxhalls