Sounds to me like you're not getting enough vacuum from the inlet pipe going to the turbo. I'd hazard a guess and say that's your problem right there ;).
The majority of the vacuum needed comes from that TB port that you stated you capped off.
If the BOV is still surging, you can try to drill out the vac. fitting slightly larger to try and help with it. If you're comfortable with doing it that is...
I would suggest dissasembling the BOV first before doing this to keep metal shavings out of it. Removing the filter in the vac. line...
Upgrading the fuel system will not change when the ecu decides it's time to cut fuel. You need to either fool the ecu into thinking there is less air coming in then there is, or get rid of the ecu completely.
Fuel cut will tell you when you've got too large of a turbo on the car. A stock fuel...
Aftermarket senders typically come in 1/8 NPT thread patterns and size, I've searched for several different gauges before and all of them came in that size. What's the M16X1.5 for?
Isn't the temp sensors 1/8 NPT? If so, then that's what you need, not that hard to find at a local hardware store, boating place, possibly even a plumbing store.
If you're worried about losing the temp sensor but still want the aftermarket sender in that location, just get a tee fitting and put it in there and you still have both.
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