Went very well considering its Sunday and had a nightmare on getting any kind of pipe and bolts... Apparently M8x20mm bolts are like gold dust at most places open on a Sunday!
Anyway, managed to solve the leak, again it was the stat not the cooler, still no idea how the lower bolt could work its way loose?...
Before, mid removal... Already removed and cut the pipe in half that connects to the EGR itself, meant I could keep the threaded collar that holds the lower oval blank in place...
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Thanks again to @Spelly for the idea of using an old aircon pipe, nearly resorted to 15mm copper pipe as the EGR Cooler is 16mm, but the 18mm aircon pipe jams in nicely and allowed me to fit a good shape that followed the flow of the EGR cooler without fouling the stat
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Also allowed me to use the rubber cushioning, not sure it will need it as its free from touching the block or other pipes due to the shape, but just positioned them to where they could do when pushed...
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All finished, looks like its meant to be there
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Just need to pinch 2 strut top bolts of my breaker now (more recycling) so I can add my blanking plate to the exhaust manifold, then its ready to go on tomo or Tuesday at the garage
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