Thanks Greg, Paskal. Still experiencing quite serious issues - to the extent that I may have to abandon my plans to take the car to Europe the week after next which is a real shame...
As a reminder :
- Fuel injection pump and fuel injectors completely refurbished by the same guy who did Greg's. Came back looking brand new.
- Turbo rebuilt and upgraded to hybrids by the same guy who did Greg's
- New Bosch MAF sensor fitted (genuine article, sourced from Autudoc)
- Bosch 3.1 bar MAP sensor fitted (supplied by Darkside Developments - so definitely genuine). This was a replacement for another Bosch 3.1 bar MAP sensor that I installed during the original rebuild to double check this was not the culprit.
- Bosch 4 bar fuel rail pressure sensor (again genuine)
Plus Do88 intercooler and associated upgraded pipework etc.
I have checked (and actually re-done) all of the upgraded sensor wiring. For the MAP and fuel pressure sensors I sourced new connectors with pigtail wiring and used heat shrink solder connectors to splice. Re-did these yesterday to make doubly sure the solder had correctly penetrated (it had).
I did notice that the turbo vacuum hoses are old - and in places, softened by oil. These may be collapsing under vacuum, though not sure if this would cause the issues I'm experiencing. Will renew with silicon replacements this weekend
I did another run last night and the car initially ran quite well - felt responsive under low throttle openings as I allowed it to warm up. Gradually increased the throttle openings once the car was warm and then did a hard pull in second. This resulted in similar symptoms - lots of black smoke, struggling to rev beyond about 3,200 rpm. From this point onwards, the engine struggled to rev beyond about 2,300rpm - and I took it easy from that point to nurse it home.
Checked for OBD errors and had two after this run :
- ECM-0002 Fuel volume control valve - Faulty signal
- ECM-089 Fuel pressure control valve : Faulty signal
The fuel volume control valve is new (replaced as part of the injection pump refurb). The wiring to the plug attached to it was (slightly) exposed at the point it entered the plug - though not shorting. I've tidied this up and insulated both wires - would ideally like to renew the plug but really struggling to locate it online.. Any suggestions?
Will take the car out again later today - though I'd be amazed if the fettling of the fuel valve made any difference..
Running out of ideas as to what to do next so any suggestions very welcome..