Problems after servicing bongo myself

[thedogsbollox]

I got a bit fed up paying my garage £280 to service the Bongo so reverted back to doing the job myself. I have done it several times without a hitch but today in 32degrees heat i had some problems. All filters replaced and oil topped up. Started up the engine and i know from past experience to give it a good rev and it dies when the air reaches the pump, then as i have done before i turn the starter and pump the bulb on top of the filter housing. Previously it would cough and splutter a bit and then eventually she would expel the air and carry on as normal. Not this time. kept coughing and spluttering and wouldn't rev up. seemed only on a couple of cylinders. After a while of doing this i figured it wasn't bleeding out the air. The only thing that is different now from then is a new fuel pump(second hand actually) and then i noticed a leak in this pipe here


I was going to remove the hose and cut a portion off the end and then replace to get a seal but when i went to remove it, it sprayed fuel all over the place. It was under real pressure. I moved the little clip from it's own indentation a little so it could get a better grip and this seems to have sealed it. I then set about loosening the injector pipes at the injectors. I couldnt get at the leftmost one but was able to bleed air out of the other 3. It now starts roughly and revs up but with a cough in the middle of the revving up. When i lift off the throttle the engine revs down then shakes violently and dies. Is it just a case of having to bleed that last injector or could there be something else i am missing?

[Simon Jones]

I've changed fuel filter twice & both times it started fine without bleeding. I'm not a diesel expert, but would have thought that any air in the injector pipes will soon be expelled when 2000+ psi of fuel is pushed through the system. I think you should replace the leaky rubber pipe first as that may be introducing air into the system where you don't want it. I think technically, you are supposed to replace all the rubber fuel hoses after about 10 years, so they've probably become hardened and once they've been disturbed, the spring clips will not be able to make a good seal. You can buy the right size pipe at Halfords so my suggestion would be to start by replacing the 2 pipes between filter and injector pump first.

Also try loosen the fuel filler cap in case it's a allowing a vacuum to be created in the tank.