EGR - mine is a little different

[Jules59]

I have the 2 plates but my EGR system looks different from the one shown in various instructions.
Where do I put them ?
There appears to be one obvious answer; at both end of the long horizontal pipe which runs down right side of engine next to the fuel pipes and joins the angled air intake pipe at the front.
But is this correct?

Pics of my engine attached.
PS what is that cast box on the left side of engine , above the wastegate actuator ?

[dave_aber]

Hmmmm...

The 2000 model must differ from the '97 model then. I agree that you have effectively blanked the EGR, by fitting the rear plate in line after the valve instead of before it.

I have a much smaller single valve at the back of the head, as per the various factsheets / diagrams you have already seen.

I don't have anything above the exhaust manifold like that big cast unit.

http://picasaweb.google.co.uk/lh/photo/ ... directlink.

Is there a feed into this unit from the manifold itself, at the rear end of it?

[Jules59]

Ive found the correct pic on lush projects

http://www.lushprojects.com/bongopartsm ... o=.html#21

There are 2 EGR valves - (both 20-300)

I think I need to block off 2 pipes as they seem to attach to both EGR valaves:

The long one on the right side (20-31X)
and also the short 90 degree one on the left hand side (20-310)


Im still not sure what that "plenum chamber " thing does - clearly you dont have it !

[bongoben]

Don't know what the lump above the turbo actually does but it's
used to heat or cool something and is generally fitted to the
"Super Economy" engine with the electronic fuel injector pump.

Bottom left hose is coolant flow from cylinder head.

Top right hose is return to thermostat casting.

Top left hose is the air bleed pipe as the coolant flow uses the
original bleed connection.

I do know it's handy to use the front fixing bolt for a TM2 sensor
as it accurately reflects the cylinder head coolant temperature.

[mikeonb4c]

Cripes - don't recognise any of that on my '95 diesel

[Jules59]

Don't know what the lump above the turbo actually does but it's
used to heat or cool something and is generally fitted to the
"Super Economy" engine with the electronic fuel injector pump.

Bottom left hose is coolant flow from cylinder head.

Top right hose is return to thermostat casting.

Top left hose is the air bleed pipe as the coolant flow uses the
original bleed connection.

I do know it's handy to use the front fixing bolt for a TM2 sensor
as it accurately reflects the cylinder head coolant temperature.

I wonder if that "plenum" uses the hot exhaust gases that are sucked through it forming the EGR flow, to heat up the coolant more quickly and thus is part of the "cold region " pack which my bongo has (twin batteries , switchable exhaust valve etc).

Not sure if I should if I should blank off the EGR after all now. Need some advice from someone who knows about these later engines.

[Jules59]

I wonder if that "plenum" uses the hot exhaust gases that are sucked through it forming the EGR flow, to heat up the coolant more quickly and thus is part of the "cold region " pack which my bongo has (twin batteries , switchable exhaust valve etc).

Or on second thoughts it could be a heat-exchanger designed to cool the EGR gases and so increase their density prior to recombustion. This to me seems more likely.

[dandywarhol]

Don't know what the lump above the turbo actually does but it's
used to heat or cool something and is generally fitted to the
"Super Economy" engine with the electronic fuel injector pump.

Bottom left hose is coolant flow from cylinder head.

Top right hose is return to thermostat casting.

Top left hose is the air bleed pipe as the coolant flow uses the
original bleed connection.

I do know it's handy to use the front fixing bolt for a TM2 sensor
as it accurately reflects the cylinder head coolant temperature.

Fwe chrissakes don't tell widdowson - he's spent the last year designing super cooling system diagrams......................

[widdowson2008]

Don't know what the lump above the turbo actually does but it's
used to heat or cool something and is generally fitted to the
"Super Economy" engine with the electronic fuel injector pump.

Bottom left hose is coolant flow from cylinder head.

Top right hose is return to thermostat casting.

Top left hose is the air bleed pipe as the coolant flow uses the
original bleed connection.

I do know it's handy to use the front fixing bolt for a TM2 sensor
as it accurately reflects the cylinder head coolant temperature.

Fwe chrissakes don't tell widdowson - he's spent the last year designing super cooling system diagrams......................

WHAAAAAAAAAAAAAAAAAATTTTT?

Actually Alan, I know it feels like a year, but the whole thing kicked off on 3rd November - not that long ago really (just feels like a year!!!!!)

[splitpin]

Jules59, I have same type of engine and blanked off both ends of pipe on drivers side of engine which is shown in your first photo. Did this quite awhile back and didn't notice any difference in performance but engine runs a touch cooler after blanking. I did it mainly to stop all that black crud being fed back into inlet. Have monitored fuel consumption and over 1500 miles it has averaged just short of 32mpg, but I have light right foot. Hope this is of some help.

[Jules59]

Splitpin. Thanks for that info. I'll have a go at doing that this week.