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Hi, if you look back on old threads I had exactly the same problem, I rang Vokera and they were most unhelpful, no matter what I did I couldn't get the boiler to fire with the case on. All the could tell me was that I had an air flow problem. I gave up in the end and told the landlord to call Vokera out. I will call the tenant later and see if they managed to fix it. The only thing I didn't do was to remove the flue restrictor, if there is one or clean the heat exchanger with a blade. The boiler has aslo run for a couple of years without any problems. Let me know if you get yours going,
I'd go with replacing the venturi as previously mentioned as only a tiny build up of debris is needed to give a low differential across the aps (top venturi normally at fault it can also get dirt into shaft which cant be seen and needs a small screwdriver to clean)
The front casing isnt squashing the silicone tubes or the tubes are holed? If its had a new aps check that the small (tiny) screws have been used to connect the bracket to the aps otherwise it may have punctured the casing. One other thing you can try is remove the rolling pin shaped cylinder out of the latent heat exchanger (if fitted). Cant think of anything else to try.
Came across with same problem, did clean everything out, dismantled flue to check the pass ways. All clean, hoovered out latent hx, fan clean. APS seems to be working correctly as managed to get the boiler firing with the case closed for some time. It used to run with case on until hot, then could not fire up again for a while. Same story - about 3 years old. Still not running. Any of you managed to get it up and running? I shall try to replace venturis if can source quickly ones, also suspecting a fan is not spinning fast enough. There is no sign of wear tho, bearings looking spot on, smooth spin, no noise just doesn't work for no reason.