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OK, remedied.. replaced the vacuum hoses and all is well, actuator was working fine again.. on inspection of the original hoses found that none were obviously split but they weren't in great condition. Hope that my little adventure and diagnosis will be of help to some others.. :)

OK, here's where I'm at thus far. rewired the spot lights and everything re-installed. fired up and checked.. W/G actuator now is NOT moving (bobbing away like usual) went for a drive around the block regardless. found that it will willing rev to 4000rpm, but will only hit max 15psi boost...

Cheers for the warm welcome Old.Tony, Yeah well aware of the effects of over oiling and am very careful of it for that reason. it seems to rev freely, but restricted.. which led me to think it was intake side or possibly blockage in the exhaust, but that seems unlikely. I'm yet to start it...

OK first post here, and this is the issue I'm having aswell. so to bring you up to speed with my Nav.. 2007 STX T/D, Manual - Spanish Built Plazmaman hotside pipe EGR Block Off K&N Panel Filter (For Road Use - switch it when going off road ie Hardly ever) YD25 Double Row Timing Chain Direct...