Yes, I used a torque wrench set to 15 ft/lbs.
When bolting on a block off plate, 1 bolt torqued no problem.

The second doesn't feel like it wants to crank down. It tightens....just kind of feels a little bit ****ed up.

It's leaking, not cause of the bolt but because the gasket is done.

SO what are my options to try and "fix" a partially (not totally stripped) bolt hole in the intake manifold.

1. buy a 8mmx1.25 tap and try to clean the threads up a bit
2. buy a couple 8mmx1.25 studs and loctite them then just use nuts and lock washers to tighten down the egr plate. I think this could work, really. The threads are still "okay". I think the threads still have enough to hold the stud as a nut pulls the plate tight.
3. Helicoil or some other thread fixer (this is my least favorite option) I really don't wanna drill out the holes bigger than they are.

Any advice would be awesome. I know I'm not the only retard that has stripped a bolt hole in the intake manifold on these cars.

thanks

It's the bottom bolt that's in question. i was just feeling around behind that bolt and it feels like that hole goes all the way through. Similar to the throttle body bolts. The top bolt needs to be short so it doesn't bottom out but if the bottom goes all the way through, then a nut could be put on the back. There's room for one.

Can anyone confirm that the bottom hole on the egr flange goes all the way through the intake manifold?

rethread the hole, and if that does not work helicoil it

or you could just buy a new manifold, stock (im assuming you have a stock one) aren't that expensive

I just found some pics of a stock manifold, that bottom bolt hole goes all the way through....If the re-tap doesn't work, which I think it will, then I'm gonna try a longer bolt on the bottom and put a nut on the backside....That's a bit easier than swapping manifolds

I would try to chase the threads first before you go near with with a tap. Those usually work to clean up slightly damaged threads, and there's no danger of cutting unnecessary threads and making the hole useless. If that doesn't work, loctite+stud. If that doesn't work, drilling and tapping for a larger size (helicoil or just tapping it) are your only options.

Thread chaser or helicoil it...When you put a new gasket in make sure to put some high temp silicone on both sides of the gasket to seal it properly so it won't leak...

I guess I'm unfamiliar with a thread chaser. I was just gonna get a tap the same size. 8x1.25 and run it through. Is that different? Also... No one thinks a nut on the backside will work? I really don't wanna make hole bigger

Thread chasers clean out/ fix threads, taps create new threads. If you run a tap through it, you run the risk of cutting new threads (on top of the old ones) and getting one hell of a mess on your hands. Honestly, I only use taps if you're cutting new threads, for existing ones (even damaged ones), only use chasers.

Okay....got it. I'm having a hard time find a thread chaser locally. In the 8mmx1.25 size...or any size for that matter.

Also, what High Temp silicone sealant should I use. I have some black high temp RTV stuff but is the Ultra Grey Permatec RTV the stuff I wanna use?

Thanks

You want to use the high temp "copper" sealant. Its in the orange tube, works great.