I took a look comparing your tune to mine, I know your engine setup is at least close to mine: 2.9" pulley, 60# Siemens injectors though difference in purchase year could mean different specs.
There's a surprising amount of differences in the tunes. I sent a copy of my tune to you, check for the PM. I think you should pull up yours in VCM Editor and open mine as a compare file and take a look.
Some differences are minimal, such as the target idle rpm chart and values for the MAF calibration. But there are others like the primary VE table that are a large % different. I agree with Gtstorey that the dynamic airflow effectively being turned off seems pointless and likely should be turned back on but could mean someone was in the middle of making adjustments.
Your injector control option values are entirely different than mine, maybe the 60# Siemens injectors aren't actually the same that we have but if they are then the tuner took a completely different approach than ZZP does now. I don't know enough to say whether your spark or fuel tabs have better or worse setups than mine, but they are very different which seems odd. I didn't do the tune on mine to know why my tune has the certain values or if yours is wrong.
When it comes to low boost:
- Your 1st gear boost limit is 75% and it's being handled by the engine correctly
- There's a 'torque mult' table for stead state boost and your tune is set to 0, mine is set to the max of 1. From a quick look this is just for cruising allowable boost, but if your throttle pedal % is funky then this could be preventing boost when you try to get on the throttle.
link to HPTuners description
I wouldn't be concerned about the 'accelerator pedal position' being more than 100% at all. I'd actually be concerned that it's not going high enough, mine goes to 255% when WOT. The 'throttle position (SAE)'; is what is charted in white in the top section and pins at 88.2 when full throttle. My throttle value goes from ~18-88.2% but accelerator pedal position goes from 0-255%:
Make sure to adjust your speedometer to match your tire size here. The pulses per mile is just your 'VSS pulses per rev' multiplied by your 'VSS tire revs per dist'. I think the 2 'Dist' values should be the same unless you're trying to run a larger spare tire. Your values here are still the original Cobalt values.
About the misfires:
My LSJ also started life in the Goblin with a huge amount of misfires:
I fixed it by going from the stock LSJ and pulley to the stage 2 kit with injectors/pulley/tuning. What I didn't realize at the time was my fuel pump regulator had failed closed and was over pressuring the entire fuel system. I think the injector replacement was necessary but I think it was caused by living at max pump pressure for some time. I didn't actually have an external leak due to over pressure but I didn't check the injectors to see if they were able to fully close after 15 years of use. I really suggest using a fuel pressure tester on the fuel rail to confirm if you're getting a nice 58psi or at least 55-60psi, anything else could be part of your problem.
Part of the 60# injector tuning was to desensitize the misfire counter and disable the misfire CEL code, adjust the idle RPM to higher than stock, and all of the fuel table value changes. Inherent to many of the 60# injectors is a slight misfire at idle for the LSJ from what I understand from ZZP, even if tuned as best possible.
