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Throttle pedal position sensor is working fine according to Hawkeye. I found the throttle had been set to 3 track in the ECU, not sure why and reset it to 2. Not that it made any difference. Crank sensor is about the only thing i haven't touched/changed.

Whats the straw that broke the camels back? Auto box fill plug is rounded out (not by me). While it might seem minor, I not sure that I can be bothered with this any more. And I know it needs some serious rust repairs (bulkhead) before the next MOT. I just wanted to get it running right before...

Yes, stall test still 2200-2300rpm. And can confirm injector clearances set as suggested.

I have it running up to 230kPa MAP/130kPa boost, with 5 threads showing on the wastegate. I'll check the roughness again tomorrow but remember seeing 2-3rpm on each cylinder when I scrolled through yesterday. I'll grab the ECU number tomorrow, but I do know it starts MSB

Yes but to get the boost I had to wind the wastgate actuator in way more than I should. Limiting the amount the wastegate opens quite a lot more than is normal to get the same level of boost, or gas flowing through the turbine side with less being bypassed. To me that points to issues there...

If i was certain a different turbo would fix it then I'd splash a bit more cash. But frankly I'm 100s of quid and 4 solid days into chasing my tail with it now and ultimately I need to decide what to do with it and how much more to throw at it. I think sierrafery mentioned about exhaust...

I'm close to giving up with this now. Swapped on the new wastegate actuator. Even with it wound right in max MAP was 180kPa, so that was a waste of money. With the original fitted max MAP is back to 215-220 with 10 threads showing. Tightened it up to 5 threads showing and got over boost...

Ordered a new one to try.

I just tightened it another 1.5 turns. Now 9 threads showing and still only see 215kPa. Connecting the wastegate directly to the boost hose, bypassing the modulator, I only get 208kPa with the same wastegate setting. No visible signs of leaks at the exhaust manifold (sooting). Going to try...

I did tighten the wastegate 2 turns. Checked boost again this morning, still 215kPa. Checked injector clearances, all were correct Finished replacing the intercooler hoses all originals were OK and not delaminated. Steel pipe in good condition, looks like it was recently replaced. Clamped...

I'll try that tomorrow. I say its boosting as I am seeing 215kPa MAP on the Hawkeye live data at max load

I will check them tomorrow. The old pump was clean when removed. All the hose clips are OK, and it is boosting to the correct pressure.

It's on standard size tyres on 17" rims. As far as the exhaust goes, it has no cat (being EU2) and the rest looks ok, at least from the outside. I've replaced the intercooler to EGR delete hose when I did the delete, but I haven't done the others yet, but that one was in good condition. I am...

Not at all. It actually isn't making the power it should. I know what these should drive like...

Interesting, so MAF does nothing on EU2 without the EGR? I read the injector codes off the tops of injectors when I did the harness. Then checked them in the ECU with my Hawkeye. They all match. It was my ex's father who had the top end work done, and even before that it was down on power (i...

EU2. I just put a new injector harness in as there was some oil at the ECU. Hasn't made any difference, but it needed doing anyway While I was in there I also checked the injector codes and they are all set correctly in the ECU.

With the MAF unplugged it runs about the same, if not a little better. New Siemens MAF on the way....

Ok, back on this again. I am getting to the point that it's a fuel delivery issue. All of the sensor readings are OK, it's flowing the air (according to the MAF) and making the boost it should, but is still down on power and I think it's just not getting enough fuel. Regardless so far I've done...

Ok, got some data. MAF - 40-45 idle, 550 full load at max rpm Ambient pressure 99kPa with 1kPa drop at full load Ambient temp - ok MAP - 215kPa at full load and stable to max rpm IAT - within range Coolant temp - within range Fuel temp - within range

Thanks, very helpful list that. I'll get some real data on the way home from work tonight and report back