Just fitted a Synergy2 to our '06 TD4 Manual - and it's going again - panick over !! 
Got the kit, read the instructions several times - 4 plugs and some cable ties how hard can it be?
Changed out the intercooler hoses for a nice shiny set of blue silicone ones while it was in pieces and repainted the EGR bypass (rust under the paint!! only been on less than a year).
Took off the air filter cover to access MAF and fitted the 5 pin plugs taking care to align Ron's white mark correctly with the loom plug - all ok.
Fitted the TU plugs to the Fuel Pressure Sensor - loom to TU cable socket easy but TU plug into sensor seemed stiff but went in (or so I thought).
Put it all back together, both sections of Synergy2 switched off and started up - no throttle response and engine management light on - oh b***er.
IT'S started raining now double b***er - so quickly disconnected TU cable and plugged loom back into sensor - started ok , engine management light went off after a few seconds and revvs ok - phew! :doh:
Ron's instructions warn that fitting the sensor plug the wrong way round will cause these symtoms - so this morning - in the dry - I rechecked the TU connections. I had done them right - So I investigated why the TU plug was tight into the sensor.
The attached diagram shows the Loom and Sensor plug & socket and the TU (Synergy2) plug & socket details. The Synergy plug has a wider spacing on the lower two lugs than the sensor socket - I trimmed off the two lower lugs and the plug now engages smoothly and snaps into the sensor as it should.
The loom plug fitted into the TU socket ok as that has a single wide lower slot (narrower lugs went in ok).
I assume that the misfitted plug was not connecting to the sensor correctly - hence the christmas lights on the dash and total lack of accelerator control.
Hope this helps anyone who may have a similar experience???
It's now fitted and initial tests were with MAF section turned off (only done 30K) and TU set to 2 - very impressive, much lower down pulling power and smoother engine feel - no smoke.
Turned the MAF section on and the tickover became smoother and seemed to pull better up to 1.5k revs.
Have also fitted the remote switch so can select TU section to; Off, 1 or 2 at start-up.
Now need to try it for a while to see what settings seem best.
Missus is well impressed with the improved drive (she drove back from Stratford on Avon (M40) yesterday without the Synergy2 and noticed the changes today immediately).
Changed the insurance to Adrian Flux last month and now have EGR Bypass, Cruise Control and Synergy2 listed on insurance with a cheaper premium -
By Gum this Forum ain't arf GOOD.
Got the kit, read the instructions several times - 4 plugs and some cable ties how hard can it be?
Changed out the intercooler hoses for a nice shiny set of blue silicone ones while it was in pieces and repainted the EGR bypass (rust under the paint!! only been on less than a year).
Took off the air filter cover to access MAF and fitted the 5 pin plugs taking care to align Ron's white mark correctly with the loom plug - all ok.
Fitted the TU plugs to the Fuel Pressure Sensor - loom to TU cable socket easy but TU plug into sensor seemed stiff but went in (or so I thought).
Put it all back together, both sections of Synergy2 switched off and started up - no throttle response and engine management light on - oh b***er.
IT'S started raining now double b***er - so quickly disconnected TU cable and plugged loom back into sensor - started ok , engine management light went off after a few seconds and revvs ok - phew! :doh:
Ron's instructions warn that fitting the sensor plug the wrong way round will cause these symtoms - so this morning - in the dry - I rechecked the TU connections. I had done them right - So I investigated why the TU plug was tight into the sensor.
The attached diagram shows the Loom and Sensor plug & socket and the TU (Synergy2) plug & socket details. The Synergy plug has a wider spacing on the lower two lugs than the sensor socket - I trimmed off the two lower lugs and the plug now engages smoothly and snaps into the sensor as it should.
The loom plug fitted into the TU socket ok as that has a single wide lower slot (narrower lugs went in ok).
I assume that the misfitted plug was not connecting to the sensor correctly - hence the christmas lights on the dash and total lack of accelerator control.
Hope this helps anyone who may have a similar experience???
It's now fitted and initial tests were with MAF section turned off (only done 30K) and TU set to 2 - very impressive, much lower down pulling power and smoother engine feel - no smoke.
Turned the MAF section on and the tickover became smoother and seemed to pull better up to 1.5k revs.
Have also fitted the remote switch so can select TU section to; Off, 1 or 2 at start-up.
Now need to try it for a while to see what settings seem best.
Missus is well impressed with the improved drive (she drove back from Stratford on Avon (M40) yesterday without the Synergy2 and noticed the changes today immediately).
Changed the insurance to Adrian Flux last month and now have EGR Bypass, Cruise Control and Synergy2 listed on insurance with a cheaper premium -
By Gum this Forum ain't arf GOOD.
