egr delete + intake manifold clean + random problem fixings of another friends car...
i always underestimate how long it takes because of broken bolts etc :/ both studs on the turbo egr port snapped with almost no effort. the nuts on them were so far gone not even an 11mm easy out fit on them. crazy. tried vice grips to get them out, but failed. cut flush with grinder and did best i could to drill them out, but one of them either through my not getting the drill spot on or not, threads were unusable. other one was fine. so reamed that out for a 10mm flywheel bolt (previously used, i always save them to put in my random bolt stash, they come in handy), and then of course had to ream out the holes for the gasket + block-off plate. wish i had a better quality + organized set of bits. lot of time wasted sorting thru drill bits that were dull, or just plain cheap and break...
couple of the egr pipe allen bolts stripped (despite given them a whack with hammer). cut egr pipe out in place with grinder to help access.
an egr cooler bolt stripped. normally those torx/allen bolts i place a bit in and then give a whack with a small hammer to try and "unfreeze" it, but this time i skipped that. maybe it wouldn't have stripped had i done that. with egr pipe out of the way, manhandled it back and forth a bit with that egr pipe cut out and then cut with grinder again on the tab with the stuck screw.
egr was completely nasty:
took a bit of time + mess with paint thinner and brushes on a baking tray after scraping the bulk of it out. then torched it and let it burn itself out as it caught fire

then more pipe brush, some more paint thinner, brushing, + brake cleaner, one more torch/burn, then final brushing to get the last bits of dried flaky stuff out. sure environmentally friendly to have that egr on the car, now that all that crap simply has to be released back out into nature in order to clean it so the car doesn't run like crap.
ASV was leaking a lot of oil (and surely some boost) as usual, so gutted that and reamed out the hole to tap with 12x1.5 bolt + copper crush washer to seal. sawzall to cut the egr valve "piston" out.
tested the tune again, made adjustments.. drove great. then go to bring the car back the next day after some other little adjustments, at first drove great, then seemed to not be boosting. putzed around with numbers for a bit until i realized it had to be the unlikely random hardware error or boost leak or something. did the n75 test with vcds and lo and behold, the n75 valve all the sudden is only putting out 5hg max. ***. swap in another used n75 valve and it gets 24hg, re-log, make couple adjustments and wayyyy better
but had been noticing a odd subtle highish pitched sounds that could possibly be a boost leak, so went over things again, and noticed the lower pancake pip to turbo (which has the o-ring + clip connection) was all wet with oilly sludge. hate those over-priced crappy o-rings. but what i do to fix those is clean it all up, put a few rounds of teflon tape in the groove and then reinstall the old oring over that so now it's a snugger fit and good as new (have done this fix to BEW pipes before and still holding boost years later).
retest/relog, still the odd sound, but it sounds too cyclical to be a boost/exhaust leak, so i think it's just some random belt noise that's cropped up *shrug*. did a bunch of high boost pulls and the boost pipe connection showing no signs of leaks.