Thanks for your suggestions! I'm really lost to be honest. They initially said it was because I had a faulty water temp sensor (which I did). However I'm annoyed that they did their full diagnostics check but didn't at least call me to ask whether id still like it mapped with the faulty sensor (it obviously affected the remap result slightly). But now they are saying I need a new actuator? I'm lost, totally outright lost.....?
We would not map the car if it was not safe to map, ( we turn away 4-5 car per week because the are not safe to tune) the G62 coolant temp sensor fault makes the the map use a correction table to compensate for the fuel and timing, the gains and losses from these correction are small 4-5bhp +/-. Your coolant temp was running 78deg tops, there optimised output would be at 90-100deg. I would say 90% of the cars we remap and that get remapped have the common G62 fault code anf never no need to refuse a car due to this issue as its only a £25 fix and 5 mins.
We was happy to map the car with the G62 fault as it was only going to effect your mpg, but no worse than it was when you was driving it stock, the main reason for being down on the potential power was/is due to the age and wear on the car as mentioned. The G62 coolant temp fault code was pointed out to you more so because it was there pre and post remap and we didnt want you to think the remap had caused the issues if you ever went to get your codes read afterward.
The actuator is spring weak, the car was down on power a little when it came in around 140bhp "ish" if i remember? we then mapped th car best we could with the hardware which gave a nice torque band but tappered off at the top end due to the actuator opening up on its own merits which has lost you around 15-20bhp on the potential peak bhp numbers.
We added our external spring pre load tester while the car was on the dyno and the boost held nice to 191bhp, showing the rest of the car was spot on and just the high miles on the cars hardware was the limiting factor to making 190bhp.
Again 6 out of 10 AGUs which come in for remaps with 100K+ tend to be around 15-18bhp down on the peak power, most people are happy and stick with a reduced peak hp reading, some go next step and go ko3s.
Jim did mention on the day and when your called back your options for more power at the top end.
You options are:
1, Find a good used oem k03 actuator which has enough spring load life left in it to produce the 190bhp
2, Find a good quality used k03s
3, Get Forge actuator with yellow spring, but more time on the remapping would be needed to set it up correct.
Its up to you how much you want to spend and how much peak power numbers your after, we can only advise you of your options.
Nick
