G40 Boost Return Valve Setting And More...

[forbes-1234]

Hi Guys,

Hoping someone can offer me some advice.
I have recently purchased a G40 with some engine modifications.

Boost Return Mod
250cc G60 Injectors
R1 Spec Charger
Toothed Charger Belt (65mm Pulley)
PSD ECU Chip (suited to mods)
Front Mount Intercooler

First off, my boost pipe blew off due to a dodgey bend sections that allowed virtually no purchase for a retaining clip.
This was sorted with a proper ali pipe and some heavy duty Mikalor clamps.
However now the engine does not run as well as it did when I first bought the car, poor throttle response, lower boost levels (topping at around 0.8 Bar) and also hunts on idle and occasionally stalls on warm up.

When I am driving and put my foot down it sounds like I have a boost leak, however I have checked for leaks and am 99% sure I have no leaks at anyone of my boost pipe joins. It sounds like the boost is leaking past the boost return valve, how should this be set?

Boost return valve fully closed at what throttle position?
Throttle 1/4 open
Throttle 1/2 open
Throttle 3/4 open
WOT

I am guessing the hunting for idle and stalling on warum could be due to a dodgey ecu temp sender or lambda sensor?
I will check resistance valves of the temp sensor tonight and add my results.
The engine also smells like it is overfuelling, I don't have an AFR gauge in the car so don't know any specific values, it just smells very rich from 1/2 throttle to WOT.

Could this be the mapping on the chip not being correct?
Do people favour different chip manufactureres?
I was thinking of swapping the chip out for a PPP chip Map #G40003
Recommended mods for chip being - ported charger, 250cc injectors, 65mm pulley, larger intercooler and colder spark plugs.
I'm not sure of the spec of the current chip, it may be suited to a cammed engine, and my engine isn't cammed, I will have to check the number on the chip.
Where can I find a listing of the PSD chips?

Any help or a point in the right direction will be appreciated.

Thanks,

[Jezza-7]

I had a psd chip once and it was overfuelling on the rolling road. Then 2 weeks later it melted a piston.

Have you tried (with engine off and bonnet open) putting your foot down on the accel pedal and at the same time leaning out the car to see the position of the butterfly valve?

Have you checked all the boost mod pipes to make sure they have been blanked properly?

Could be that the rubber bung that holds the accelerator cable to the bracket is slipped or the metal clip is letting it slip. Had a problem on my car once like that.