Newbies Techie Teething problems

Technical questions and answers about the Mazda Bongo

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Klikchik
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Newbies Techie Teething problems

Post by Klikchik » Sun Jul 10, 2011 3:35 pm

After lots of help on this fab forum and searching the UK we have finally taken the plunge and bought our 1st Bongo, 'Libby'. (short for Liberty!)

Very excited as you can imagine, but Im afraid to say we're having a few teething problems. :(

She's a 2001 2.5TD 4WD AFT, silver over grey with removeable rear conversion. We got her from Bill at Campercraft who was very helpful but to avoid taking her back on a 6 hour round trip in the future he has suggested buying a warranty and using our local mechanic and unfortunately she is there now. :(

As a fresh import with 60,000 miles on the clock, body wise she's in good nick, has had a respray for scratches and Bills mechanic says mechanically shes one of the best he's seen. :)

However, after picking her up on 25th June, we werent 20 miles up the road and she started to scream on acceleration and felt very sluggish.

Less worryingly the airbag light also flashes all the time and the central locking makes a bizarre loud buzzing noise on the front passenger side and it doesnt lock.

Our local mechanic tells me her EGR pipe, thread and gasket have gone and there may be something wrong with the turbo, but we wont know til these are fixed. He has found a replacement gasket but hasnt the pipe and says he will try to get one on Monday.

dave_aber on this forum has been great and given me the following advice but I would welcome other comments which may help please.

"Screaming on acceleration, sounds a bit like a slipping belt, can be a warped exhaust manifold and associated sheared manifold stud - I have had this on mine. However, an exhaust leak from the EGR piping would probably sound the same so Gary's diagnosis is most likely spot on. In fact the only job I had done by a garage since buying the Bongo was to have the exhaust manifold removed, skimmed, broken stud extracted and all refitted.
Now, the EGR is there to satisfy the Japanese emissions and nothing else - it in fact slows you down a wee bit. The first thing I did was to blank it off. If Gary's saying the threaded bit has gone, presumably he means where the EGR pipe joins the back of the exhaust manifold? The russian Bongo club blank the EGR off here by putting a coin (2 Roubles IIRC) in the joint and re-connecting it. (I have used a pair of blanking plates further along the pipework - one at the valve and one at the inlet manifold.) Some folks have just removed the pipe from the exhaust manifold and welded up the hole. Either way, it needs to not leak, but can be blanked off completely.

Central locking - sounds like a faulty solenoid unit in the passenger's door. Should be a cheap fix, and it's an easy part to replace. Bill may source one for you? My central locking also makes a weird squeak / moan from the back on unlocking for some reason.

The airbag light flashing I'll have to look up - I'm sure I have seen it on the forum somewhere but can't remember what it means. Maybe it's an airbag fault? You never know though - the 'Hold' light is used to indicate loads of different faults for example. "


Im afraid Im not engine savvy and dont know how bad this is but we are desperate to get away in her as you can imagine!!
Not quite what we envisaged for our long awaited dream! :(
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"Do what you love, love what you do.....

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Klikchik
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Joined: Mon Apr 25, 2011 12:52 am
Location: Moray, Scotland

Re: Newbies Techie Teething problems

Post by Klikchik » Sun Jul 17, 2011 11:23 pm

Apologies for my newbie ramblings. Wasn't looking for a miracle online diagnosis, just some reassurance and a general idea if it's 'the done thing' to blank off or remove the EGR pipe. Gasket replaced anyway and there's a big difference :)
Now I'm just learning to get to know all her little foibles.
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missfixit70
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Re: Newbies Techie Teething problems

Post by missfixit70 » Sun Jul 17, 2011 11:36 pm

Post 99 diesel bongos have been known to have issues with the drive by wire fuel pump & with the variable vane turbo, here are a few threads that may help (or not)

http://www.igmaynard.co.uk/bongo/forum/ ... turbo+vane

http://www.igmaynard.co.uk/bongo/forum/ ... turbo+vane

http://www.igmaynard.co.uk/bongo/forum/ ... =3&t=37784

A lot of us have removed or blanked the egr, doesn't really affect anything on the old shape bongos up to 99 as it is basically an add on to satisfy Jap emissions requirements, but haven't looked into the setup on the post 99 to see if it's tied into the system a bit more.
Flashing airbag light is likely the clock spring, I'm sure this has come up before, a search should reveal some answers.
Good luck getting it sorted, & keep us posted
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321Away
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Re: Newbies Techie Teething problems

Post by 321Away » Mon Jul 18, 2011 8:49 am

the airbag light is usually the 'clockspring' behind the wheel, sometimes they only flash when the wheel is turned a certain way, not a difficult fix, but usually fairly expensive (about £150) part to replace.

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Klikchik
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Re: Newbies Techie Teething problems

Post by Klikchik » Thu Jul 21, 2011 10:56 am

Thanks for the replies folks.

Think I may be wise to leave well alone now that she seems to be running well. have bookmarked the links though, just in case. [-o<
Will get my garage to check out the clock spring.

Now got a high pitched squealing when sitting at 60 to investigate. Really annoying when driving along on the dual carriage way, sounds like something needs oiled. Bill from campercraft thought it might have been normal turbo noise as it comes on when hitting the throttle but it's intensely annoying so there must be something not right! :?

Onto that learning curve again...... :|
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missfixit70
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Re: Newbies Techie Teething problems

Post by missfixit70 » Thu Jul 21, 2011 12:22 pm

High pitched squealing could be, as Dave Aber said, warped/leaking exhaust manifold, look for a bit of dark staining where exhaust gases are escaping & signs that nuts are missing off the end of studs, I'd have thought Campercraft would have checked that out though :-k . Belts? or just that the seats aren't tightened down properly & you're hearing more than you should? Check the seat clips are tight to fasten down, if they are slack at all, then bend em a bit more to tighten them (a wee tap or 3 with a hammer :wink: ) Could it even be the tops of the doors not sealing properly, a common bongo issue, they seem to "pull out" a bit at speed.
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