Help - keep breaking down - over fuelling

[rustyp]

Hello there, I have an annoying problem with my Bongo which has been fine until now. It is a 2.5 TD.

When it gets up to working temperature and particularly in traffic the idle would go a bit lumpy then it would stall unless throttle applied, often I would have to put it in neutral and rev it at which point there is lots of smoke as it is over-fuelling massively. Eventually it would cut-out. After a while it would run for a bit when re-started then do it all over again.

New glow plugs helped a little but broke down

So....

Took it to my mates garage, diagnosed that the temp sensor under the inlet manifold was knackered so was changed (as well as coolant, oil and filter, fuel filter as it was due a service) and it ran like a dream yesterday and today until this evening when once it warmed up and was going up a long hill it wouldn't rev over 2000rpm, it would just stutter and die, below this was OK but after a while it just cut out altogether smoking like mad and stuttering.

Any pointers?

Cheers Russ

[rustyp]

This may or may not be a factor (I don't think so)

I was running on 50/50 Diesel and Bio-Diesel and ran fantastically for 200KMS then the issues started. I filled the tank up to the brim as it was 1/2 full so now only on 1/4 Bio-diesel.

Also

Having just searched about my running problems (to no avail so far) I have discovered the banjo filter - potentially if this was blocked would this affect the running in this way?

Cheers Russ

[stilldesperate]

Hi Russ,

Feel sure that I read about running on other than "proper" Diesel can loosen all the Cr*p that's in the fuel lines, and the banjo filter can block as a result.

I've no experience of this, but think you might be on the right lines - 200Km's might have pulled enough Cr*p through to block it.

I'm sure some of the more knowledgeable (like Missfixit and others) have posted about this, mebbe a search on the forum would help.

SD

[daveblueozzie]

The simple answer is yes it might cause the problem, if its blocked it is starving fuel to the engine, if you've been running on veg oil, it will in effect have cleaned all your fuel lines , so any crud will end up in the fuel filter, the banjo filter is the last protection for any crap getting into the jets. clean the banjo and with any luck that will sort the problem out.
Another good tip is to fill the fuel filter with injector cleaning fluid ,this will do exactly what it says on the label.

[rustyp]

Trouble is the Bongo seems to be over-fuelling not being starved of fuel

It only happens when the Bongo has warmed up fully after a few miles and then not all the time - my mate at the Garage took it for a good long run and left it ticking over a couple times.

What happens is it splutters lots as described above, surging away seemingly like the cold start circuit is chucking in lots of fuel when it is hot after a few miles. Engine is fine when cold.

The bio-fuel might simply be a red-herring!

Russ

[westonwarrior]

I would trust the guys as above, the symptoms have come up a few times and although I dont understand it as, as you say it looks like too much fuel, it usualy is the filters

could also be ablockage in the air system filter etc
or does yours have the cold weather set up 2 main batteries as the exhaust valve may be shut

[rustyp]

I would trust the guys as above, the symptoms have come up a few times and although I dont understand it as, as you say it looks like too much fuel, it usualy is the filters

could also be a blockage in the air system filter etc
or does yours have the cold weather set up 2 main batteries as the exhaust valve may be shut

Fuel filter has been changed but not the banjo, haven't checked the air filter but hasn't done many miles. I don't understand about the cold weather set-up and the exhaust valve??

Thanks for replies - Russ

[westonwarrior]

some come from the north of Japan and come with 2 batteries and is known as a cold weather kit

there is an exhaust valve which closes in cold weather and is known to stick restricting exhaust.

If you have that there will be a switch to the right and lower of the steering wheel with the picture of an engine on it

[rustyp]

There was space for an extra battery so my brother who imported fitted one. I may have even pressed that button looking for the spotlights!!!!

What does that button do? Whereabouts is the exhaust valve? After the turbo? Does it block off the exhaust to warm it up quicker?

Gonna go and have a look later.....

[rustyp]

Annoyingly I only have 1 key and I posted it through the letterbox of my mate's garage!!!

[rustyp]

Is this valve supposed to move out of the way automatically when the engine is hot or is it down to the driver?

Russ

[teenmal]

Is this valve supposed to move out of the way automatically when the engine is hot or is it down to the driver?

Russ

Hi Rust,
I would advise you to remove and clean the strainer (banjo filter))first and then take it from there.
It can cause all sorts of problems if it is gunged up.

Cheers Malc.

[scanner]

Those are the classic symtoms of a blocked fuel filter - I know because I suffered them last night and had to change the filter - did so and cured them.
That is the main filter not the banjo BTW - I've suffered this 3 times now and never found cleaning the banjo on it's own does any good

Don't think that just 'cos it was changed recently it can't be the filter that's blocked - it can be, I've found it can block almost instantly.
Mine was perfectly OK Thursday - topped up with veg oil yesterday before a longish trip and it was chugging away last night.
Mine just doesn't seem to like a big dose of veg oil for some reason.

But check if you have the valve in the exhaust because if that sticks shut it could have similar effects.

[francophile1947]

Whereabouts is the exhaust valve? After the turbo? Does it block off the exhaust to warm it up quicker?

Gonna go and have a look later.....

It's in the exhaust pipe (you can't miss it if you follow the exhaust from the engine) and it is designed to block the exhaust to help the engine warm up quicker - check the switch with the engine symbol on it.
Also, read http://www.igmaynard.co.uk/bongo/forum/ ... =3&t=29471 - local help is often available, but we do need to know where you are

[rustyp]

Will update my profile - I live in Saltash near Plymouth.

Filter was changed Friday and broke down again Saturday.

Is the exhaust valve supposed to move back out of the way automatically or is it down to the driver to switch it off?

Russ