Alfashark

Nice work on the shifter! My Audi, although a difference linkage setup, had the same ball/spring/dome setup in the pivot. The ball was effectively gone, leaving the spring to fall to the bottom of the lever with no feel as to exactly where it was or what gear you were in. Added to that the shifter knob was almost flush with the center-tunnel surround as a result. I attacked a yellow poly bush in a lathe to make a ball, fitted that and ended up with a very stiff but rifle-bolt sharp shift - That loosened up to a comfortable level after a few weeks use though.

Remap - It's not a VAG product, so unsure of the usual suspects to deal with down here but give these chaps an email and see what they can do. http://www.quantumtuning.co.nz/car-remap-tuning-remapping.aspx?Make=Hyundai&Range=Sonata

Or just use the remote to switch off the sweeping louvre function? Probably stripped a tooth on the actuator.

@V8Pete How did you find the owner of that plate you bought for the Fez?

Other alternatives which may be a bit easier to source than the A-class would be a 99-07 Skoda Fabia or VW Polo of the same era. The Fabia option is definitely remote reservoir, sitting on the opposite side of the car.

Not extending enough to make contact with the flywheel, or flywheel missing teeth.

Correct, my Superb had all that jazz... As for GT Mechtronix, try emailing them in a week or two. Seems like they have a remote office offsite and one little geezer doing all the leg work at the workshop itself, so he's probably taking a well earned rest.

Awesome result! I can wholeheartedly relate with your issues when I had my Audi - I never personally got as balls deep into playing with the control pressure as you have, I sent the car to a chap that knows more about the system than Bosch do...

Coarse-pitch prop and one of these is what you need... https://www.trademe.co.nz/a/marketplace/sports/kayaks/other/listing/2404399209

Like @00quattro00 said, I wouldn't be pulling it apart. See if you can lay hands on a spare one and either play with that or swap it in and see what happens. Either the injector insert sleeves or the o-rings will be rooted through age and heat cycles. Mine turned to powder when removing...

My 5-pot Audi did very similar things once upon a time. Since I had time to clean everything possible, just about all of the fuel and ignition side came out and was put back together after replacing only a few vacuum hoses that were well expired. Between that and reseating all electrical connections and relays, the problem disappeared so I never had to chase it further.

Also, it escapes me right now but do these use a tachymetric relay to keep the pump powered up when the engine is running?

Being a lazy bugger, I haven't checked your progress thread but when you pulled the pump/accumulator out, did everything go back exactly how it was to start with? Possible you dislodged some crap and it went into the line post accumulator which could be starving supply at the metering head?

Lush! Old enough to be terribly British, young enough to still have reasonable access to parts. Looking to EFI convert, or just bring the K-Jet up to scratch? If you can get past the usual Barry-bodges made by the uninformed, K-Jet does a pretty good job really.

EGT gauges... Overrated.