Ok chaps hitting a brick wall with this one.

Vehicle recovered in as a non start, driving to work and started to struggle, "felt like lack of fuel" but made it to the customers place of work and switched off, end of the day and non start.

Interrogation of customer revealed vehicle suffered with slightly difficult start twice in the last week but once running it was fine including a fairly long run.

Code read was clear.

Low pressure fuel feed 0.5 bar
Plumbed into intermediate pump and only 0.5 bar, clamped return and no increase in pressure so we have a knackered intermediate pump.

Checked oil level, no increase so injector seals would appear to be ok but as the vehicle has done over 120k and I wanted to see the condition of the injector bores they were changed.

Fitted new intermediate pump and now have 2.7 bar cranking rising to 6.5 bar with return clamped and a steady hold of 1 bar after cranking.

Cam timing checked with correct tools.

Pico on cam and crank shows good signal.

EGR checked and cleaned.

Independent fuel supply to eliminate bad fuel.

Relative compression test, all cylinders equal.

Towed to eliminate starter interference.

When cranking vehicle produces a certain amount of black smoke from the exhaust so fuel is being injected and VCDS on immobiliser shows all good.

During all the above tests no codes have been generated so a few things were unplugged to confirm the ECU was capable of flagging codes.

Going home now as this game is pi**ing me off, fresh head on in the morning!