Hi Darren>>>the turbo Actuator is working correct and I think your theory is wrong<<<.... HOW VERY DARE YOU!!!
Actually you are right (GIT) . I had a call today from an Andrew Evans who confirmed the position of the actuator arm as fully sucked at start-up. Thanks for that Andy.
Anyway I have had the benefit of a donor vehicle today, courtesy of a flood damaged Zafira. I tried swapping the EGR & Charge pressure sensors but neither made any difference.
Next I tried a road test with a midway setting on the actuator (held in place with vacuum applied with the Mitty Vac). It was nearly perfect & no fault codes logged either.
I was considering giving up & handing it back with a “best guess” diagnosis of maybe a faulty turbo or incorrectly set actuator. Then I had a flash of inspiration & considered that maybe the "stop screw" that limits the travel of the actuator could be set incorrectly. Not wanting to adjust it & disturb the paint from the locking nut, I decided that the professional step of placing a small nut on the protruding thread & holding it in place with a bit of blue tack, would do to prove a point. Sure enough I drove it home this evening & it is spot on.
My NEW theory is that the turbo was being stalled by the actuator arm moving too far. Maybe the vanes are fouling the impeller? I will have a play tomorrow to confirm.
This refreshes the hard learned lesson, that just because something is new, it doesn't mean its good.
Anyway I would like to thank everyone who has taken time to respond. Very informative stuff guys Thankyou!
Cheers for now
Dave (Hill)