Hi Guys - here's an Update
As per my plan, went to the fuel system to check pressure, part of which is a vaccum "behaviour check" on the regulator. I pulled the vacuum line off the regulator and low and behold, full of fuel!
This explained all the behaviour.
I pulled the injector rail off and replaced the fuel regulator ($126.00) and we are back up and running!
note: I could look right through the bottom of the regulator - a pinhole in the diaphragm.
IF you are on the road and this happens, disconnect the vacuum and plug with a bolt, use a spare/small length of vacuum line blocked off at the end and a small hose clamp to seal the regulator. That'll get you home...
So, here's a breakdown of my specific steps.
- Pulled the fuel pump relay, cranked the engine to depressurize the fuel line
- Removed the TBI plastic intake
- loosened the supply line on the right of the fuel injector rail
- Undid the bolts off fuel line clamp in the back, then the intake, then the 2 bolts holding the rail
- Undid the accelerator cables... Just pull the plastic tabs up with a screwdriver on the housing, and the clips come out. Rotate the accelerator back to rotate out the cable end.
- Unclipped the injectors (little blue pastic tabs - depressed with small srewdriver, then pulled them out a bit, then they unclipped. Undid the cam sensor. Pulled wiring harness aside. Carefully wiggled the rail/injectors out and pulled the fuel rail up to rest on top the intake.
- Undid the torx screws off the regulator and return line clamping plate.
- wiggled the regulator off the return line, and out of the fuel rail (both pressed/sealed with O rings) NOTE: used rag to catch gas in rail.
- Cleaned the intake ports (stuck fuel line host in injectors and cleaned each with WD40) as there was plenty of crap buildup which I didn't want to get on the injectors when I put back in
- Cleaned the injector Orings (all were good) - BTW best to replace - BUT I couldn't get any in time - reused old ones - put dielectric grease on each
- Did the same with new regulator Orings - pressed in return line, and rail.
- Reassembled injector rail, intake (make sure to every injector connector clicks in, and don't forget cam sensor). Connected regulator vacuum.
- Pulled the plugs and cleaned them, them put ignition housing back on, connected ignition plug
- Double-checked all connections - then restarted engine
- Fired up then died, fired up again, ran a bit rough as system cleared the excess gas (exhause was a smokin). Note: came up with a map sensor error - it eventually cleared.
- let her warm up and then took her for a run - all good.
As for the cat, since I've run too much gas into it, I do expect I'll need to replace the cat before my e-test in October. That's a job for my mechanic - a PITA without torches and a hoist.
Thanks for the input guys. Hope this helps anyone else who has this problem.