FSI failed its MOT today, been a hectic few days...
After proclaiming it finished the other day, when moving it across the yard the engine light came back, knock sensor voltage too high intermittent, manifold flaps not reaching setpoint, and no response from lambda sensor.
I removed the locking pin for the vacuum actuator I'd accidentally left in when I put it all back together, but it still didn't work.
I noticed I'd put the one way valve for the control of the actuator the wrong way round, despite photographing it before disassembly which was a delightfully easy fix.
But then my repair to the arm of the actuator failed, I had thought it would be plenty strong enough, (carbon rods and epoxy) but upon a bit of googling it turns out regular araldite is only rated for 80 degrees Celsius and no match for the hot FSI engine bay.
Because of the design of the manifold, (the travel the flaps have in the cylinder head is not enough to line up the actuator with the clearance slot needed to slide it out) the whole thing needs to be disassembled to remove the actuator, upper and lower manifold, including the high pressure fuel system...
Took it apart on Monday, repaired the actuator for a second time, this time with stainless steel wire and araldite 2011 which has a slightly higher heat resistance.
I also fixed someone's botched wiring job on the knock sensor.
Lambda error dissapeared and hasnt returned
Got it back together by Tuesday evening, but when driving it home in preparation for its MOT at 8:30 this morning (I work in my grandads workshop but the mot centre is much closer to home), having stopped to investigate a smell, I leant lightly against one of the fittings to the coolant vent pipes, which snapped of, spraying out boiling coolant.
Left it in a layby overnight, got a lift out to it this morning, bodged it enough for the MOT and topped it up with water, only for it to fail on some brake stuff (Handbrake efficiency less then 50% being the main one)
Tomorrow I rebuild the brakes
. 
