A brief story, engine let go in the van so I got an exchange unit as was easiest option, fitted all ok new filters fuel included, bled the system then tried to start it splutters and chucked a load of smoke out but won't ever fire. I checked fault codes and it read rail pressure low, when I read the live data it's only showing 400-500psi which is no where near enough.

I've checked leak off on injectors and nothing comes out. I've checked the return and only a dribble is returning.

My guess is the pump, but I've no idea why it would go all of a sudden as was perfect before? Engine dropped a rod but was running fine.

 

Are you using your original injectors / pump etc or did the new engine come with them?


If it's got low rail pressure it wont even try to inject. Sounds like it either needs injectors coding back in or it's got an air lock.

 

It's all the old system as bought a bare block, I've actually figured it out since posting this.

It is one of the injectors, which would explain the plumes of smoke as I blocked the feed and it stared up right away.