probably not get car back until Monday now, looks like am borrowing a Toyota Aygo from garage, never been in one, does it have gears, gear stick, twist and go or what...........

TO be honest I don't see why the 57mm TB can't be used. It won't make a huge difference
Hopefully the new one solves it though!

MT said can be used but best not for long journeys as it's mapped for the 60mm.
I now have a white Aygo 1L 3 cyclinders, feels quite wide when driving it, not much acceleration have to floor it to move along, does get going though, smart inside, basic cheap looking dash and controls.

Aygo returned
BeaST is back

seems smooth on the spanking new throttle body, TB plug also replaced and the wires lengthened so as to lessen the stress on them to the TB, quite tight and also are up against the edge lip of the CAIS of which I have told everyone about before.

And wouldn't start this morning again am sat here in ford on free wifi looking like a new pcm auto electrician having a look tomorrow awaiting a hire car again

Ouch money money

so was looking forward to driving to work this morning and turned key and same again, just drove home last night and stood overnight and limp mode again, recovery truck out, another half day off work.
Garage were quick on job, while I was waiting to speak to service manager he was actually unplugging the TB, plugged in my old TB while in his hand ie not on car and all fine again.
Not sure on what to make of that because a new TB also does not work either now yet the factory one does, doesn't mean if I were to drive with factory one on MR200 it won't throw a wobbly but it will clear the fault codes.
Conclusion seems to be that the PCM is struggling to read data from the upgrade TB, to it or from it not sure, spoke to head tech asked about coil pack and other stuff and he is happy no other problems, there are no other fault code other than TB and PCM.
Auto Sparky going to have a look tommorrow and were hoping it won't start again for him, see if he can detect where the data is struggling. Then new PCM will be ordered, probably put the Stage 2 185 updates on then send car to Essex somehow or other, either hire a drive or low loader because I ain't taking it and will cost me day off work again, see if garage can spare a driver but then would need to be certain it will not throw up another fault during trip, so probably best have it low loaded there and back..............££££££££££££££££££££££££

I now have a Black Aygo Fire, yes a Fire edition woop woop.............

Fire as in hot!? hahaha
I'm wondering whether it's the sensor itself in the TB that has gone. perhaps got hot from being machined out or the butterfly clearance's are a little out.
Maybe it needs the MR200 map loaded again? Not sure if you've tried that. So many things have been done/suggested that I've lost track

unlikely as car is currently on a brand new 60MM TB fitted monday, so kind of rules out it being the TB or the sensor attached to it. Not much has actually been done, new battery seemed to fix the first issue month or so ago, but we only cleared the faults by using the factory TB, then put the MR200 60mm TB back on, car worked fine until this week. Same again only this time we cleared the faults again and put a new 60mm TB on and then this morning broke down again.
PCM is clearly not reading the start up data being sent to it by the TB, otherwise when we get the car running even if by using the old TB to clear faults, the car runs usually awesome permformance, I have no running issues at all, seems to be a start up issue and PCM shutting down.

They should of narrowed it down by checking if there is a live to the sensor and a return from it on start up, also reading in the correct scale amounts. Just seems strange that it works well with the standard TB but not the 60mm. To me that's a throttle body fault rather than PCM. Unless it does eventually play up with the standard one back on it

auto electrician was looking at it today (not heard anything yet), yes agreed on original TB, can only assume the mapping is looking for specific data back from the 60mm TB which it probably is sending but not reading it whereas it may be satisfied with what the 57mm TB returns. Really have no idea myself. Ford are talking to Mountune though for extra help, will keep updates comings when I hear more.

I would of tried a new remap. Return it to standard and load completely new file. Would make it easier if you knew what figures it was looking for at the TB

more or less what I was thinking, if car has to go to Mountune then let them plug it in and see what's happening and take a new PCM there as well and load that up for me as well to bring back.

Have you already got a new PCM? a lot of money?
Like I said before, it's very rare for a PCM to actually fault. People often mistake faults on them when it is things like remap, sensors elsewhere or bad earth. A good engineer should be able to tell that, but it's very easy to mug someone off with a PCM fault

not heard anything from garage, fault codes bring up the same two every time TB and PCM.