iveco daily EGR / turbo problem

capeverde

Absolutely desperate for advice here. Brief synopsis;

Bought 57 plate van around 4 months ago, done 74k and spotless. Had new engine only 2k miles before as driver blew turbo and didnt stop in time. Since then it blew another turbo and had this replaced with a recon. At this time I bought it. On the way back from purchasing it the EGR valve went and the dealer paid for an iveco engineer to replace it at the side of the road. One of those things I thought. Then the turbo went and this was replaced with a new one. The EGR valve has since gone 3 more times and the garage cannot find a cause. Yesterday the turbo manifold hose blew off and whilst the AA put it back on I noticed white smoke from the exhaust, but it was very dark so couldnt be sure how much.

My question, is there anything linking the EGR and the turbo, that both seem to be affected and keep breaking. We have jet washed the exhaust and there was no build up, it was clean. Other than this the engine runs perfectly. The garage is a commercial specialist and has had the computer on it and it is showing no problems. At the stage where I cannot use it for fear of breaking down. Also as I bought as a business and it is over 5k, my only recourse with garage is to get to court with relevant costs. I would rather just get it fixed. As a layman it feels like there is too much pressure and when you stick the preverbial finger in one hole it blows out somewhere else.

Any advice is much appreciated.

Notmyrealname

Yes...the intercooler or the pipework to/from it. Output from turbo goes to intercooler and then to EGR and into the engine. The EGR also has a separate pipe that goes from the exhaust to the EGR to recirculate the exhaust gases in order to reduce the emissions.

The only thing I can think of is if there's some kind of restriction in the intercooler chain that the small pipe that is supposed to just pass a small amount of exhaust gases is ending up under pressure due to the restriction. This would !!!!!! up the EGR valve and it would also blow a turbo as the turbo would have a load of boost pressure designed to be sent down a 3" diameter tube being forced down a 3/4" tube.

It is trivial to bypass the intercooler - just need a suitable length of the right diameter pipe. The vehicle will run fine with an intercooler bypassed.

Something somewhere is seriously broken. These are things breaking that should do 100,000's of miles.

vax2002

patch it up and get rid.

capeverde

thanks for the replies. I have thought about getting rid, but its just passing the problem onto somebody else, which isnt how I operate. Everything else is fine, bodywork immaculate ect and I aside from potentially putting a small business in trouble by selling them goods not fit for purpose, I could do without all the hassle myself of messing about finding the right vehicle. Has to be 4.5m bed and high top. Will ask the garage if they have checked out what you said notmyrealname.

Delivery_Driver

If the turbos keep going, are they checking the sump when they replace them?Bits of broken turbo can end up in there and block oil pickups.If the turbo doesn't get a good oil feed its not going to last and the cycle goes on.
I'd also expect the intercooler to be flush/replaced after a turbo failure as it can be full of crap that will then get fed into the engine.It might not happen right away but it will make its way there.

atrixblue.-MFR-.

get rid of the EGR valve blank it off (garage can do quite easliy).

second for turbo shards in the oil feed pipes and intercooler and sump or trapped in the block.

i would be asking garage to strip down the all oil pipes and intercooler for inspection, bore cam in the cylinders to see any evidence of munched metal in there and an engine flush and sump removal to check oil pump isnt partially blocked.

forgotmyname

In what way do the turbo's fail? Stop providing boost?

Oil seals fail?

Wear on the impellers? Other?

capeverde

forgotmyname wrote: »

In what way do the turbo's fail? Stop providing boost?

Oil seals fail?

Wear on the impellers? Other?

dont know about the previous ones before i had the vehicle, but the one that went recently just released a massive cloud of white smoke. i stopped the van and called the AA. he put the computer on and said it was the turbo. garage confirmed this but didnt say how it actually failed.

forgotmyname

You need to know why it failed.

Without knowing why your just treating the symptoms and not curing the cause.

It may keep eating them, Until it destroys the engine itself.

ijmorrison

If its any help the following is what I had happen with my sisters rav td :-

Traditional turbo failure (milkfloats beeping then overtaking lol)

Had turbo rebuilt, rebalanced and tested. Reinstalled, oil change, etc ready. week later complete turbo failure. Impeller damaged again !

Turbo rebuilt ... CAT and back box replaced (BAFFLES !!!) .. oil again turbo back on .. running like a dream.

Second failure was due to the now efficient turbo managing to suck rubbish UP through the exhaust !

Expensive lesson ... DOH

forgotmyname

How can a turbo suck from the exhaust?

Sounds like the garage failed to check the oil supply or the inlet pipes for debris.

Someone else mentioned finding bits of turbo in their intercooler after they bought a car and the turbo gave up soon after, And the parts were not from the currently fitted turbo.

Just lazy or inexperienced mechanics.