First of all I believe my problem is / feels like a complete lack of torque at cruising speed. To Sondela and back with a load, I was getting 6.5 to 6.8 km/l indicated. At pull away it seems about normal. I like using Rigel ave hill as a test as it has been used on a host of different vehicles and I am used to the norm. Coming up there on Sunday brought back memories when Ford / Mazda first brought out their 2.5tdi, working with Ford we used that hill every day. That old tech 2.5tdi would have run rings around my struggling 3.2did. My son's 2.5tdi Triton with a heavier load performs a lot better. (I am not the happiest chap at the moment - I feel betrayed !!!! Spending that amount of money and it goes .... Having my son chirping me that I should have bought a Sport does not help! - I am starting to wonder if it should not have been a Toyota!!!!!).
I now need some time to calm down and think logically. Man oh man I wish we could get to the bottom of this

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Cats, your comments: In the mean time I would like to determine if the readings I am getting on my OBD2 port is consistent with others.
Highest boost value I get is 11.9. Is this correct? - What are you reading that in psi? If so then yes for an OBD reading. The OBD to me is an indication only (electrical) and as someone has mentioned (Marius?) rather use a mechanical gauge to get it set 100%. I must add that mine was a bit low and I went to serious extremes to get it spot on and the reward was very small / virtually nothing. What I am saying is, I do not think that is where the problem is. I will gladly put my mechanical gauge on for if you wish.
What should my MAF meter reading tell me? MAP sensor reads manifold pressure and with engine off also reads atmospheric which often throws people when reading turbo (ie turbo + atmospheric)
Why is my ambient intake temp often around 70-90degrees!? Is this right? Yes this is about right considering that you have hot blow by air coming from your tappet cover. I am busy putting a system together which will a) cool blow by air from the tappet cover and b) trap oil vapour and return it to the engine. For every one degree rise in intake temp, the exhaust temp rises by three !!!!
Should it not be a lot lower? Does this not indicate a blocked intercooler maybe? I have had a look at a number of intercoolers (from Fords 2.5tdi, Landrovers, etc's trouble times). I have always found a bit of oil (maybe a tablespoon full) but never blocked. The turbo boost should move most obstructions (oil) through the cooler. Because the EGR connects onto the inlet manifold there should never be any carbon (ie only oil).
Talking auto box, I paid particular attention to the auto box over the weekend. Something I also noticed (comparing Gen3 to 4) is that the Gen4 transmission does not "predict" your ideal gear as the Gen3 did so beautifully (ie as you slow down the box drops down automatically, so that when you do put your foot down, you are in exactly the right gear). The Gen4 sort of does it but not well. I often found the box changing down but only as and when I accelerated.
Anyone got a nice Gen3 engine and auto box for sale ? Anyone want a nice Gen4 engine & auto box - just kidding

........ - for now!!!!!