Turbo Problem on New Shape Bongo

[Ian]

Trevor from Halesowen has been in contact. His new shape 2001 2.5TD 4WD has an issue with the turbo.

"My Bongo has had intermittent problems with the engine management (glowplug) warning light coming on after 10 minutes or so with a resultant loss of power. It has been into the garage a couple times and they have been unable to isolate the problem. A diagnostic check showed the problem to be the Boost Pressure Valve which was changed but this has failed to rectify the problem.

There is no loss of power until the temperature reaches its normal level or after about 15 minutes running.
This weekend having looked closer at the Bongo both at cold and up to temperature the problem appears to be the actuator arm external to turbo. At cold this appears to move freely when revved, but when warm the arm appears to stick in the UP position and the warning light comes on. Taking a flat head screwdriver you can move the arm down and the warning light goes off and the hydraulics seem to work for a while until the arm sticks again and the warning light comes back on."

I provided Trevor with a summary of the other known issues that have been reported here on the Forum (summarized in a fact sheet in the member's area) and his garage have now come back with the following:

... I went on to check the vacuum solenoid switch (brown 2 pin switch with 3 vac pipes as described in the fact sheet). With the engine warm and the warning light on therefore no turbo assistance I can't honestly say that I can feel the switch clicking with the engine running. If the 2 vertical pipes at the near end of the switch are removed and joined together the operating rod moves fully down giving maximum deflection as described in the fact sheet. Does this mean that the switch is working or not working?? If it's not working then I feel we have found the problem. With the engine off I have applied 12v to the switch and it does indeed click on and off.

So there are 2 questions:

a) Does it sound like the solenoid switch is working or not working?
b) What is the page number & part number for this item on Lush Projects?

[rita]

I believe this system may have an inline air filter, long shot but might be worth checking / temp bypass.

Intermittent faults are a pain in the ####.

[briwy]

What fuel are you using?
We had this problem twice when using supermarket diesel, absolutely no problems using branded fuel.