Inlet Manifold work - now "limp mode"
Firstly let me just quickly introduce myself before I beg for help!! I'm Phil and I have owned a 159SW 1.9JTDM for about 18months. In that time I have been reading these forums religiously picking up lots of good info, I have gone down the route as many have of removing/drilling out DPF and having a remap to remove the regen and the EGR and boost the performance..... That has all been great with no issues for about a year now.
Recently inspired by a post seen on here the other week I decided it was time to take off the inlet manifold and try to do something about the leaky swirl-flaps, which I believe are like teh EGR and DPF a pointeless complication to the engine.
I set above removing the manifold from the car (an epic task, but not too complicated), cleaned out all of the gunk (there was plenty) and then decided that I would disconnect the flaps from the actuator (leaving the actuator electrically connected) and also remove the swirl flaps from the shaft that holds them into the manifold, then to finish the job I sealed the shafts into the manifold with exhaust paste..... so basically I no longer have swirl flaps, just 1 solid thin shaft in place of each flap.
After putting it back together, this took longer than expected as the woodruff key from the fuel pump disappeared into abyss!! I was confident that everything was connected, especially as I follwed a very thorough Vauxhall workshop guide as posted on here. I started the car (1st time) and found that it idled at 1500rpm had No turbo pressure and is limited to 3500rpm. If I press and hold the brake pedal the revs drop down to normal idle speed, but upon release it builds back up to 1500rpm.
So far I have tried the following (unsuccessfully):
Changed for a new MAP sensor because it appeared to be pressure related.
Disconnected ECU for a day to reset it.
Checked all vacuum lines.
Checked all electrical connections.
Used Fiat ECU scan to test all actuators and ensure they were functioning (they all were).
Used Fiat ECU scan to read fault codes (there are none).
Now I'm really struggling, my next steps are to follow the fault finding guides in the E-learn tool as there seem to be some useful sensor checks etc. If I can't find anything here then I think I'm going to have to do the job again and maybe try a new manifold with swirl flaps in place, but I don't really want to go here.
I have read on Vauxhall engines about people glueing the swirl flaps open with no issues (which is the same as what I've done), therefore I don't think my modification should cause this problem.
Any suggestions of what to check, would be gratefully received. I assume what I'm experiencing is "limp mode" but I don't understand why there are no faults recorded to give me a clue whats going on!!