December 5, 2003 Modifications
Here's what I got in the mail today sent from my Cosworth parts supplier.  It's a replacement actuator known throughout the Cossie world as a -31 actuator.  It's infamously called this only because the part number of this actuator ends with -31.  What it means to a Cosworth owner is it allows more boost over the stock 9 psi. 

As I have a Stage one chip, I can dial in 15 psi while the chip takes care of the fuel mapping at those levels.  To dial over 15 psi is possible using this actuator, however the stock (yellow) injectors cannot handle the extra needed fuel - hence  the chip isn't programmed to map at higher than 15psi levels.  Apparently, i'm told you can set this actuator to 20psi, which makes sense to me since it has the slack to set at even a higher boost setting.
Heres another view.  As it gets screwed into the wastgate shaft, the more boost is dialed in.  As u can see there is more threads left for future additional boost.  The screw locks the shaft in place
Norice the gold actuator to the left.  That's the new -31 installed. Here's the wastgate shaft being held onto the door lever using nothing more than a bent-around paperclip!  The original pin fastener was of a lighter metal!!
That's the pathetic stock boost actuator.  It too is threaded (as if you want LESS than 9 psi!!).  Man, it has seen better days, eh?
Well, adding a K&N air filter, good set of plugs, Stage 1 chip and this actuator was all that is needed to make anywhere from 250hp+.  If you have a 3" exhaust and a bigger intercooler (RS500-style) then you'll probably be nearing the 280hp point.  I don't plan on making any more horespower, although I am planning a 3" exhaust in the future.  Now I can go out there and kick some Prelude Type R ass.  Wait a minute!  I coulda done that with the Stage 1 chip and the stock 9psi!!  LOL!!  I already had the K&N, spark plugs changed & Stage 1 chip already.  This mod completes the Stage 1 conversion.
NOTICE TO MERKUR OWNERS

If your a 5 speed Merkur owner, you're probably thinking to yourself  "So what??  15 psi is the standard boost pressure on my car".  Your right.  Both standard Cosworths and Merkurs come with the same size .48 T3 turbo.  Keep in mind one major difference.  With just 15psi on a Cosworth, you're in between 250-280hp at the flywheel in European DIN HP figures. 

The best you'll get with a stock Merkur is 177hp SAE - just a bit more than the V6 the XR4i came with.  However as we all know, add an intercooler, big VAM, K&N, take off the knock sensor plug, add a PE chip/ECU, 3" exhaust and a Gillis valve set to 15psi  and you're making a good, say 230~260 hp SAE.  Still under a Stage 1 Cosworth.

How come, despite the displacement advantage of the Merkur engine?  Simple.  The better 16 valve head allows more hp naturally aspirated.  The Merkur engine makes a pathetic 88 hp off boost.  Compared to the 160-170 hp from the Cosworth engine and you'll see why the standard 8 valve Merkur (Lima) engine needs 15psi.  The head is the main culprit.  It's an awful 8 valve design.  But through good porting and some head mods, the 8 valve can be converted to a very SCARY contender!!
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