Well I disconnected the standard one on my 300 tdi years ago and get a whopping 1 bar of boost vs the 0.9 to 1.1 bar the manual says is safe

Never heard of a boost controller for a 300 tdi Or I am missing the point ?

Could it be that the sealent you used is not good and the stuff is busy seperating into it's base chemicals . There must be some sort of liquid mixed into the compound to enable it to flow ? Just guessing here of course

R u sure that's engine oil and not a mixture of "old" engine oil and diesel ? I don't think you are ever going to get it completely dry. And if it doesn't drip after 1 hour of standing it's called a "sweat" of oil

On mine the OD of the leak off V on injector 1 is slightly thinner than the V on the back of the IP. So i have a good piece of wire around that pipe connecting the two

When I change my diesel filter - I will fill the filter and run the car for 2 min's , then open the top bleed screw to get the last of the air out and sometimes i am a bit frisky on the undoing of the bolt and the jet of fuel will be 1 foot high, - that's at idle If I hand pump it it will still...

Your post re the engine dying sounds like the lift pump. They can be quite temperamental/shyte . A cheapish part and may solve your hard starting as well

The leak off pipes are connected to each other via that V looking thing. Injector 4 to me is the one nearest to the bulkhead / driver and the one side of the V doesn't have a hole to transfer fluid across and obviously wouldn't have a pipe connected to it Maybe two of the V's are in the wrong...

The banjo bolt - that connects the leak off pipes to the front of the injector pump - has given me the same issues in the past - albiet randomly I suspect the copper fitting joining the incoming leak off pipes to the return pipe was my issue, but I found copper washers somewhere and replaced...

Not a link but from my D1 workshop manual - Never had to use this section before

Well yes it's too much fuel for the amount of air it is getting, so turbo could be the issue , or a hole in the intercooler or pipes. I put a bicycle valve in my top boost hose linked to the manual gauge inside the cab in my D1 300 tdi - cheap and is a needed for diagnosing issue's That's where...

I think the brit in canada has made the same comment about the stiff springs in the clutch transmitting to the g/box and buggering it up as well

You will be moving the same "lever" that the hi/low inside the cabin is attached to/too if you get underneath the trf box So not fixing anything just a temporary get home faster Sierra is correct on the manual but as an aside i have done many many trips where I am in low range for 1000 kilo's...

No my reply was ambiguous - The selling point is to get balanced air across all cylinder's

There isn't a speed limit in unlocked low range. If you slide underneath the trf box you will be able to feel the offending lever on the top of the trf box - kinda in the middle The lever does a vertical up and down movement that you can move by hand. I cant remember which is which but if...

From the compression result's you have cylinder 2 and 3 must be getting more air than 1 and 4. This is the selling point of the twin intake thingy. Someone on here posted the fitting of such an intake a couple of month's ago

Google tells me the 300 tdi has a compression ratio of 19:1 - so at 15 psi (air pressure at sea level ) times 19 means a max of 285 psi - your readings of 400 would using my logic be way too high - of course I could have the cat by the horn's Even if it is wildly wrong the readings on cyl 2 and...

One other thing I would try is to remove the air filter and go for that same drive and see if any diff in the smoke level's. I guess I am trying to eliminate air scavenging from the sump with this test

You need a boost gauge to give you any real answer on the smoke you mentioned. Those compression numbers are good. Was it a cold or hot test ?

In saffa land we got a 4.0 L petrol V6 as well