Massive thanks to Lofty.
I bought an Audi A3 TDI 2.0 2006 in December with 120k on it. It was going great until 2 weeks ago when I noticed excessive grey smoke when pulling away from standstill and occasionally going in to limp mode when pushed hard up hills. Car wasn't using any oil and there was no water contamination etc and when it came on the turbo it went fine most of the time.
Last week it went permanently into limp mode, even after a reset via the ignition.
Googled it and started by cleaning the EGR but didn't make any difference, then found this thread and did the Mr Muscle treatment.
Took all the air system off and managed to remove the EGR pipe without removing the cooler, not a lot of room on a BKD Audi A3 but it can be done from the top, left it for 2 hours and worked the actuator arm until it moved freely and then took it for a drive, the difference is unbelievable! Its like a different car, sooo much more power than previously and no smoking or erratic idle.
Top man Lofty, this saved me a packet as the garage had already diagnosed new turbo. Have a virtual beer on me
