Panic! Poorly Bongo.

[missfixit70]

Factsheet in the members area - http://www.igmaynard.co.uk/bongo/member ... ts/EGR.pdf - or if you do a search on EGR, there are some photos & stuff somewhere, I'd stick a blank of some sort where the egr pipe enters the air intake manifold at the front drivers side of the engine, the egr valve may be jammed?

[dandywarhol]

Squirrels nuts


Sparky

A friend's Peugeot 309 caught fire when burning squirrel nuts got sucked up the air intake and ignited the fuel in the carb! The nuts were stored on top of the exhaust manifold when the car was parked up for a couple of months.

[John and Kim]

Ok, managed to find the pictures of the 'Pipe block method' and although not too clear (the EGR was invisible in one piccy and the 'removed' pipe was relocated already in the other piccy) I now now to remove the pipe from the diaphragm thingy and block it off with a bolt.

UPDATE................

OK blank'd it off, no difference at all, Bah!

ANY ideas???

Regards to all

JnK.

[dandywarhol]

As Kirsy says - blanking it off from the pipe is the only real solution - just blocking the pipe won't work if the valve is jamed open...........

Don't think thats your problem though - EGR smoke problems tends to be a gradual thing...............did you try taking off the intake pipe to check for a blockage?

[mikeonb4c]

Hi John and Kim.

My first reaction is don't panic - with luck this wil turn out to be simple. Whereabouts are you (might help us point you to a good Bongo specalist if it comes to that). Also, was Bongo from a dealer and can you get them to fix it under warranty?

If it were to be the turbo, I notice there are a couple for sale on ebay just now.

Good luck and keep posting

Mike

[bigdaddycain]

On the EGR valve thingy, I'm not sure if mine is fitted? (2005) as I can't see the pipe that you'd normally block off? I saw the piccy on here somewhere but the pipe is not there? just the one with ridged foil and the throttle cable. I will endeavour to find it, 'where it be?' (as they say in Brisol!)

JnK

and............No Badgers! Removed the filter and pipe to carb...............

I'm not suprized the EGR blanking didn't work in this case, you mention your bongo is a 2005 model?

That means you have effectively two EGR systems, one feeding from electrical pulse via your ECU, the other mechanical.

If there was a problem with the EGR, you would have a flashing "hold" light on your dash,and the ECU would default to "limp home mode".

I still suspect contaminated fuel, have you used bio diesel at all?

[John and Kim]

Thanks for all the advice, OK to answer a few questions;

The Bongo was bought privately driven home with no problems at 70-80 mph for 60 miles from Bridgewater to Bristol where I live. It has been parked on the drive for a couple of months and started on occasion to warm up the inside to let my kids play in it.

I decided to tax it this month so drove it a couple of hundred yards down the road intending to take it for a spin. I didn't really notice anything was wrong until I set off for a second time and the engine had warmed up. The engine will not rev over 2500 rpm and altho' will come out of 1st will kick down with large plumes of smoke smelling of unburnt fuel billowing out of the exhaust.

So that's all really, I've removed the air intake and blanked off the EGR pipe with no difference, even revving it in neutral has exactly the same effect. No flashing Hold light, normal diesel only a couple of months old and will tick over and rev upto 2000 rpm fine.

Will have a poke around and check cables, turbo etc.

Still hoping someone has had the same problem?

I think BELL HILL is my nearest specialist (unless anyone know any different)

Rather fix it myself tho'!

[mikeonb4c]

I can only think you'll need to eliminate things one by one, starting with checking for blockages, filter cleaning / replacement, and other stuff like EGR (some peeps remove fuel filter and fill it with pure diesel injector / cleaner then reassemble and start the engine) then moving on to stuff like the turbo, the throttle sensor (Dandywarhol recently had a problem like this) etc.

Out of interest, is coolant level good and does coolant look clear (not muddy or rusty). I can't think you have a head problem if it ran home fine and now suddently doesn't run at all.

Is it really a 2005 Bongo? I wasn't sure if they even manufactured them that late. Is it a 'registered in UK in 2005' model.

On garages, I can't think where Bell Hill are. There's Protech in Nailsea I think I recall reading, and maybe Algys the Bongo importers in Bristol could steer you right - worth asking them.

Good luck and keep us posted.

[John and Kim]

OK, Bell Hill's near Bath but Nailsea may be nearer for me.

Meant 1995!

Water level is fine and the engine comes upto the the 10:30 temperature fine as previously stated is fine upto 2000 rpm but then just wont rev past that even with my foot flat on the floor. I don't know enough about the engine to go much further (but have no problem with mechanics) but maybe some sensor error altho' then I guess a flashing hold light?

I removed the pipe on the 'cold' side of the turbo and the vanes spin fine and besides the smoke coming out the exhaust if definitely unburnt fuel and not oil.

I'm still open to any suggestions but will have no time after this weekend so it'll be off to the garage, just hope it is something simple and therefore not too expensive.

I will post the results!

Anyone?

JnK.

[maxheadroom]

Just a thought try driving without the fuel cap on

[haydn callow]

Try ABS...South Liberty Lane ..Ashton..Bristol.....BS3 2TW...if it's nearer

[mikeonb4c]

One suggestion that came up recently was to disconnect the fuel line from beyond the fuel filter and let it use some clean diesel from a container, bypassing the filters. If it then runs fine, you have a good idea of the problem. Also, have you tried some diesel injector cleaner in case it helps?

[phedders]

Erm I might be being daft - but is one or more pot not getting compression? ie head or valve problem or possiblly leakage around a plug?

Just thinking unburnt fuel, lack of power etc.

[teenmal]

Erm I might be being daft - but is one or more pot not getting compression? ie head or valve problem or possiblly leakage around a plug?

Just thinking unburnt fuel, lack of power etc.

Good reply Phedders,the engine might only be running on 3 cylinders due to a faulty injector(s).

Mal..

[John and Kim]

Thanks to all for all your suggestions. Alas I have run out of time so have taken it to the garage.

Thanks to Haydn for the reommendation but did wonder why I couldn't find them.

It's ADS Automotive, Unit 200, South Liberty Lane, Bristol; 0117 9635999

They're picking it up tomorrow.

I'll let you know how I get on.

JnK.