one problem solved another arises lol...egr/manifold

[Dan1066]

So today i tackled my EGR valve and manifold flap unit with the target to cure my black smoke , i didnt bother cleaning it i thought id just ahead and replace it. Apart from the rear most bolt being a proper little ****$r to get at it was a nice little job to do overall.

I did however spot a little problem as i was taking it all apart, those dreaded intake manifold bolts / Egr bolts, were not so tight and sure enough there are stripped out, i have managed to get the egr and flap on quite well its just not fully faced on and therefore is causing me slight boost issue. It starts and runs fine but when rev or accelerate its a little rough from around 1800-2200 then goes like a damn rocket, (it has been remapped i suspect),

Has anyone encountered this horrible design and use of material and how have you gone about fixing it? My best attempt is to try and source some slightly longer bolts with washers and nuts to clamp it down properly. Ive got a damn mot on tuesday and im away from home right now with work till the 4th armed only with a small socket set one screwdriver and one allen key ....typical lol ! oh and im in Grimsby for sins so if anyone is local and wants to lovingly help out a fellow audi owner that'd be brilliant haha. (54 plate A3 tdi2.0)

Dan

[Rob69]

Sounds like it needs helicoils fitting, on the 2 litre I think this could only be done with the manifold off.

[Dan1066]

Yes it might be, im going to to see a friend in the stores from work tomorrow and hopefully get some nuts and bolts that will fit it for now and get it right for the mot then i will look at a new intake manifold maybe. I hate it when things arent right, it'll bother me for ages lol

[Dan1066]

Well just a quick up date, i have managed to get some nuts and bolts from the faithfull storeman onsite and with some jigery and pokery all is bolted up safe and well again, ive just nipped home for a cheeky 30hr bank holiday visit while site is quiet a 130 miles drive home and its running better than ever, plenty of power very little black smoke apart from the obvious puff when driven hard. happy days again

[Rob69]

Always handy to have a pal in the stores!