Alfashark

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...

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.

Try and find someone involved with the Mainland Muscle Car series - I remember from my long nights working in a servo, I read a bit in Aussie Muscle Car mag about how the various teams in the 70s in the Aussie Touring Car champs would tweak live axles using the methods Adoom mentioned above.

Yes. The Fabia, in 180,000km and 12 years of ownership has cost about $1500 for the 12 routine oil+ filter services required by the manual in that time. Maybe another $200 for the cam belt and water pump.

Yes.

Define small. http://www.exidebatteries.co.nz/battery-range/passenger/Endurance Have a look at that list and check each one's spec out for CCA vs Dimensions. A DIN55 is a smallish battery in my books - 175H x 175W x 242L.

A mate had one and was convinced that both the VS and his VN were around the 2T mark... He quickly ran out of places to attack with a hole-saw in the pursuit of weight reduction. And achieved fuck all in the process.

Did you mean a VS Ute? Because there's no way they're more than 1600-1700kg unless you're lugging a spare boat anchor or two around on the back, given a VS V8 sedan tipped the scales at a bees dick under 1500kg