Boost Leak and Evap Smoke Machine

[axxeman]

Hello good people. Still having troubles with my 04 TDCi and was thinking of finding someone with the above to pinpoint the boost leak ...
It is playing up with:
1. Black smoke under hard acceleration.
2. Lower mpg.
3. Stinking of fumes from the get-go
4. Increased turbo whine under load.
5. Noisier tick over (with a ticking type of rhythmic pattern on idle that wasn't there before).
6. Visible smoke in the headlights at night when stopping after a run. It comes out of the front of the van immediately upon stopping.

My chap has checked all the hoses and turbo+waste gate+egr and come up dry. I am beginning to suspect the intercooler itself and will ask him about that this week.

Any thoughts? (No fault codes, so EML, no LHM and if you drive it with only gentle acceleration, it's pretty much OK)

Greg