Galaxy Wont Run with Turbo Pipe Connected?!

[CGalaxyF]

Hi, new to this and hoping for some advice!! Had some running faults with Galaxy 1.9 TDi (130 ASZ) which kept stalling and cutting out. Before I had a chance to take a look it cut out and failed to restart. Have started to look and found that when I remove the pipe going from egr to intercooler the engine will fire up and run, throwing smoke out of the turbo in the process!!  Also when it runs now I have a very bad oil leak which appears to be coming from somewhere around the EGR? I know these suffer badly with both EGR and turbo faults so am I likely to have to replace both turbo and EGR to fix? Or is there something I'm missing which will fix both faults? Because it wont run with egr/turbo pipe connected does this mean the turbo is faulty? Or blocked etc? Any help/advice/suggestions greatly appreciated in advance! Thanks.

[Chrispb]

Hello and
You say you removed the turbo pipe from intercooler to EGR, did you disconnect the sensor connected to this pipe?
This is the boost pressure sensor and is part of the system that controls the turbo.
A certain amount of black smoke from exhaust when running engine with that pipe disconnected would be expected.
But do you mean smoke coming from the removed pipe

The oil leaking from the small hole on the EGR is down to wear inside the valve, it is normal to have an amount of oil passing through the EGR valve and pipe work, this is not normally from the turbo but from crankcase fumes that enter the air charge pipe connected by the small pipe connected to the cam cover.

It may well be your EGR is clogged with sooty carbon deposits and could well be stuck in the open position
Have a read of the following
https://www.fordmpv.com/smf2/reference-library/galaxy-mk2-intake-manifold-cleaning/msg85/#msg85

Before you start removing anything get yourself a Vagcom lead from ebay and download the latest VCDS free from Ross- Tech and with the aid of a laptop you can scan your own car for possible fault codes which can help diagnose the problem.
http://www.ebay.co.uk/itm/Blue-VAG-COM-OBD2-OBDII-409-1-KKL-USB-Car-Diagnostic-Cable-Interface-Tool-UK-/260887176465?pt=UK_Diagnostic_Tools_Equipment&hash=item3cbe166511

[CGalaxyF]

hi there, thanks for ur quick reply, have a lead but no codes in car at all. smoke coming from the pipe coming from egr valve and also from turbo pipe on left side of engine once i'd removed the air intake. have removed the egr now and is absolutely smothered in soot so cleaning this and replacing the gaskets will hopefully cure that problem. still worried about the fact car wont run with pipe on though? is that normal when an egr is sooted up? i just thought it affected the running/idle etc? am i likely to have to change the turbo to cure this? thanks again.

[Mirez]

If the EGR is stuck in the open position then you can get this issue, its unusual for it not to start though its just normally smoky and lacks power. Smoke coming from the pope from the turbo? Is that the one from turbo to intercooler and if so which side, turbo side or intercooler side? You shouldn't be getting any smoke around there - although there will be blow by gas so you may get oil vapour in the air which looks a little like steam - at idle though you really shouldn't be getting much  as that would indicate engine wear. How many miles as this done?

[CGalaxyF]

was coming from pipe that comes from egr valve with map sensor in? was more like steam than smoke now you say that! It is high miles done 140k. Just worried about the non start with that pipe connected? I've never heard of EGR causing that before!

[Chrispb]

You didn't say whether you unplugged MAP sensor when you run engine with charge pipe off, really surprised nothing logged on vagcom if you run engine with either MAP or MAF disconnected they will register a fault.
Try measuring block 003 and look at the live data this shows the EGR operation at tickover, EGR duty cycle on tickover should be around 60% if it's showing 84% it's closed if it's 4% it's fully open

[CGalaxyF]

I did unplug map sensor and wouldnt run, until i took the pipe off?! Have just removed the turbo and have attached the picture? Assume this is the problem.........!!

[Chrispb]

Picture not very clear but does look totally knackered, you will also want to remove the rest of the air charge pipes and intercooler as you will most certainly have debris in them