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That's the dogs bollox mate. Love it.

Under the bonnet on the drivers side. From memory, I think it's clipped to the engine fuse box mounting bracket.

Probably replaced by an App :)

+1, Check the voltage in and out of the glow plug relay, does it click when you turn the ignition on ? When it's cold my EDC auto will not start without working plugs.

I had to use an old belt to hold the pulley, needed a friend to hold the grips while I hung off the spanner!!

Does the bearing actually need replacing? Mine seemed OK so I just kept the new bearing as a spare and changed the coupling. I'm on my 4th coupling now but still running the original bearing.

Agree it sounds like over boosting, are you positive the wastegate isn't stuck shut ? My EDC was exactly the same as soon as it hit those revs the power was cut temporarily, made it very difficult to get up steep hills.

also very good https://www.tayna.co.uk/Car-Batteries-C48.html

I recently stripped and refitted mine as the end-plate was leaking. I didn't set TDC either but can't see any leaks. Are you able to nip up the bolts now that the engine has been running ? Did you use a new gasket between the pump and the block ?

+1

There are a few types of right-angled USB extensions cables that might fit without the need for any cutting. Might be worth having a look at some to see if you think they may fit before you chop anything.

Isn't that the front of the car above the windscreen ?

You won't be disappointed with Cooper STTs, I fitted Coopers to replace my BFG MTs and i much prefer the Coopers both on and off road although the BFGs were well worn so that might be a bit unfair to the BFGs. I think the Coopers are also quieter on tarmac, you can only really hear them at low...

Does sound like the TPS.

It's a real pig to move with the whole lot still on the engine. Mine was stuck solid but was on the bench anyway so it was easy to free up. A 16mm spanner fits nicely if you can twist it with some mole grips you may get away with it on the car.

Jap import 300's have water cooled EGRs and I think I still have mine in the shed along with the required pipework. You're more than welcome to it if you want it.

Well done for getting it sorted and well done for taking the time to post details of the solution to help others :):):)

Me too !! manifold on the bench. Also snapped an alternator bolt, noticed the p-gasket was leaking and found out that the manifold gasket was in 2 bits which finally fixed the oil leak down that side of the engine. 10 minute job turned into 2 days. how I laughed :cool:

Soak the bolts in WD40 or similar as many times as you can before you do it. Drilling out a snapped stud and re-tapping is a real pain. Ask me how i know :p

I didn't notice any real difference when I removed the egr on my EDC auto but mine occasionally stuck open which left me with no power and lots of black smoke so I removed it. If yours is working properly you may not notice a difference but it will eventually cause you problems so get in there...