Thanks Lynall, some things to have a look at there when I get home this evening. The fact that I also had a factory MAF sensor fitted which showed the same symptoms pretty much rules out the sensor in my mind. I'm going to put my MAF sensor on my girlfriends 2003 G4 to see if the fault transfers with it- but I have to put the cylinder head back on first- it's on it's way back from having a cracked injector port welded up. I know my pump is OK as I had the tank out a couple of months ago and the pump and tank interior were as clean as a whistle. Interestingly though, I had to change the injector seals on Saturday as the car was getting intermittently hard to start in the morning for the previous week. The copper washers that came out weren't in bad shape but I did find a lot of carbon particles in Nos 3 & 4 injector ports which I can only imagine were deposits from combustion gasses leaking past the washers. That also explains why the starting problem was intermittent- if the engine stopped with compression on Nos 3 or 4 cylinders it would bleed off past the washers and push fuel back to the tank. If not, it would start normally.
I'll check the throttle position later with the Hawkeye. I think the EU3 models actually have a triple track and it all looked good last time I looked but worth looking again for the time it will take.
You should take a look into the EGR to see how gunked up it is eventually get rid of it, on facelifts a quite common problem is that the catalyst is clogged and restricts the gas flow so the turbo can't spin up well... go somewhere where the noise it's not an issue, undo partially the downpipe to have a gap there and go for a short drive...if it runs better you have the answer
Thanks Sierrafery. I'm thinking along the lines of eliminating the EGR valve as there is, I believe, a direct link with the MAF output. I'm going to mechanically lock it closed and the air valve open and see what happens. I'm not in a rush to get rid of it as I can see diesel emissions getting more and more attention at MoT time in the future as diesels become less popular environmentally. Besides, all my driving is on windy country lanes (low speed, high power, hence why this "MAF" flat spot is a problem) where the EGR valve is, or should be, rarely open anyway. I'll see how clean it is when I do that, but when I changed the MAP sensor a while back, it wasn't gunged at all. The new one did put a little bit more spring in it's step though.
Interesting thought re the CAT- I hadn't considered that, but I then can't understand how unplugging the MAF would suddenly clear it. I'll put it on my list of things to try though- I've been around long enough to know that logic is often buried deep and hard to find!
My gut feeling is that with the MAF connected, either the wastegate is being opened at low revs or the ECU is restricting fuel flow. I'll try and get some more quantative data to go on.