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Did you put that little metal gasket back on the EGR? Maybe sucking air through and unseen space somehwere?

This does help and thanks for the reply. I didn't even know if the 1.6 had the VTCS, so that helps too. I'll do some further probing on the clangy noise, but the noise is consistent and doesn't sound like something like a screw is flopping around in there. But if the screw is stuck somewhere...

I have the car balanced at the edge of a cliff with my foot on the rear bumper, ready to let it go... Heres the situation. Ive been searching all over for my specific issue. Have found lots like it, none matching exactly. Seeking help from The Great Council. Here are the stats: 2000 Protg...