Bongo Fury

I've taken this from Allans website because it adds to the debate:

If your EGR system is working as it should, there's no reason to do anything to it. In other words, "If it aint broke, don't fix it".

Commonly, problems are due to a faulty valve and/or pipe operation. The system can block and the valve remain permanently open. Excess smoke or engine knock can be present. EGR pipes can leak and manifold or turbo pressure is lost, resulting in reduction in power.

Use one plate at the EGR end to blank off a valve problem. Use one at the inlet manifold end to blank off a pipe problem. Blank at both ends for both problems.

Because the EGR on ours is leaking, and the new parts are pricey, we are going to blank it. But if it was working it should, we wouldn't do anything to it.

The easiest way to bypass the EGR system is to pull the vacuum pipe off the valve and blank it with a solid rivit or similar - a 5 minute job - but only if the EGR diaphragm isn't leaking. Thanks to veg ian for the pic.........

Hi
I've just fitted our Bongo with Allan's EGR blanking kit....will post results
Helen

Hi
Results , as promised, Well, I'd say stupendous....I would expect that my EGR valve must have been gunged , or partially functioning . Just done 200 Km. and the difference was remarkable.
Helen

Did you clean the inlet pipe out as well?

Hi Scanner
No, 'fraid not, but the results I have got are very good. Perhaps, when the weather warms up, we'll tackle the manifold.
Cheers
Helen

Helen said

Results , as promised, Well, I'd say stupendous

Stupendous in what way Helen - maybe a stupid question, but what were the results tat you noticed?

Rhod
PS Off down south to Chassis Clean for the next couple of days to get the van's underparts anti-salted, so not being rude & ignoring any reply!

Hi Rhod
As I said in my previous post, I suspect that my EGR was malfunctioning. I imagine that it had slowly gummed up leading to a gradual diminution in performance which had gone unnoticed. From the posts I have read, , blanking off the EGR has different results from Bongo to Bongo, from a small result to something like mine. I noticed a distinct improvement in smooth running from tickover all the way through, and the engine was more lively today with 4 adults on board , than it normally is with just Tony and myself, and on the way back from the shops (about 90Km.) we also had a month's food and supplies for 2 families for a month...around100- 150Kg. and the Bongo still had no problems. Throttle response is also a bit quicker, especially on overtaking. Today was dense mist, though, and I find that damp air always aids performance, nevertheless I feel for a small outlay in time spent, it's well worth it to fit the kit I bought (Allan's blanking kit). I'll do some fuel comparisons, and I suspect the fuel useage is a little less.
I hope that answers your question...anything further , just ask.
Cheers
Helen

Thanks Helen
It's on my list of things to do, but not at the top, since I don't think mine is giving problems yet - so was interested in seeing what benefits you'd seen. Think it's still on the back burner.... Very useful feedback though - thanks for sharing it.

Well, just blanked both ends of mine. I will keep you posted on my findings.

Thanks for reminding me about this thread. I did the EGR mod last October and was going to post some MPG results. I have it all on a spreadsheet and I'll post the full figures eventually but I'm off to New Zealand tomorrow so I haven't the time at the moment. A quick summary though...

I bought the Bongo in October 2006 and it very soon settled to an average of just over 22 mpg. I don't do a lot of motorway driving - mostly it's fairly short journeys. I fitted a set of fuel magnets about this time last year and these made not the slightest bit of difference. I fitted the EGR mod in October last year and again the difference in mpg is negligible. I've filled up 10 times since I fitted the mod and it averages out at 22.22 mpg. Overall, since I got the Bongo, it averages at 22.16.

I'll post the full figures when I get back from NZ.

Hi All,

I fitted Allan's kit at the back end of last summer.

Fitted because there was a crack in the weld at the EGR pipe into the manifold.

I've not noticed a change in MPG but there was a very noticeable change in the 'tone' of the engine and the vibrations have changed, particularly at cold idle.

Grahame

Ok, so I thought I'd give this a bash and went with dandywarhol's suggestion above of blocking off the pipe with a bolt or similar. Thanks for the pic BTW, this helped explain the idea very well.

The process went smoothly but now when I have the engine running, rev up and then release, I get black smoke coming from what looks to be the EGR valve.

Anyone know what this means? Can it be a leaking diaphragm or something else like a leak between the EGR and the manifold (exhaust thingy)?

(Note, I ain't a mechanic so I hope I'm making sense here!)

Incidentally, I've not had much luck putting the tube back on to the EGR, it's in the most inaccessible place and my hand just does not bend enough to get in there. Anyone got tips on how to re-attach the tube. I thought of using a pair of really long plyers or similar.

thanks
phil

I found another suggestion on the net to use a ball bearing to block the EGR.

The idea is you detach the tube from the other end (not the EGR end) and place a small metal ball bearing inside the tube.

The ball bearing should be big enough that it doesn't fit through the nozzle the tube attaches to. The idea I believe is the vacuum created inside the tube will suck the ball bearing through the tube until sits atop this nozzle and blocks off the EGR.

Anyone tried this?

No because if you get the diameter wrong and it's too small then it gets sucked in. Anyway it does the same thing as blocking at the other end with a bolt or peg etc. I still reckon blanking plates are best.