Blanking off the Egr

[Mel Holmes]

I've had an intermitant problem with my Bongo for about 5 months - stalling on idle when hot. It takes about half an hour of driving before it does this (and sometimes it doesn't do it at all!).Also, it's a bugger to start once stalled and takes about 15 seconds. It's been in 3 garages now (2 diesel specialists) - had the fuel lines pressure testing (fine) fuel and banjo filter replaced. Everyone has agreed it's a problem with the fuel getting through and one was convinced it was the pump (he said it would cost me a fortune to rebuild/replace)
Stew on here had a similar problem and eventually fixed it through a combination of EGR blanking, vacuum hose replacing and relocating and the addition of a fuel pump/primer.
I'm gonna start with the EGR blanking as it seems the easiest and seems to have benefits anyway. I've trawled the site here several times under loads of searches and can't seem to find any specifics. I've got the manual and located the EGR pipe running over the drivers side of the engine. It seems obvious where to blank off the front end of this at the gasket but I'm not sure about the other side (and I don't want to blank of the wrong pipe!)
It's my only vehicle at the moment and I'm hoping to drive up to Edinburgh tomorrow night.
Any help would be appreciated

[jaylee]

Hi Mel, some one else on here had an ongoing problem with a stalling Bongo/fuel getting through, they spent a fair bit of money trying to solve the problem, new parts etc...

Turned out to be a leaf in the fuel tank...!

You never know.

Found the thread... http://www.igmaynard.co.uk/bongo/forum/ ... af#p220698

And the original> http://www.igmaynard.co.uk/bongo/forum/ ... =3&t=22542

I know you probably have different symptoms, but the simple answers always elude...

[Mel Holmes]

LOL - the leaf in the fuel tank! Someone did mention a senario with gunk in the fuel tank too - maybe it's something I'll check out. My list of processes to eliminate keeps getting bigger!
I've just noticed that my Bongo is one set up for a cold weather climate - two batteries and a valve mid-way through the exhaust system. I'm not sure if this has any bearing on it.
Whereabouts do you block off the EGR at the rear? Is it underneath the EGR valve? I'm not sure yet as I've not had it apart and the illustrations in my manual are a bit open to interpretation.

[Simon Jones]

Try a search for "EGR" - there is a lot of info on here. My EGR was blanked by a previous owner at the valve end (by welding it shut!), but I cant see any advantage in doing the inlet manifold end because the circuit is already broken. Unfortunately, as it was already done, I'm not sure what difference it has made to performance, emissions & black smoke.

[Mel Holmes]

Thanks for your replies
I'm not sure if I'm missing something here but I've done all the advised searches under 'EGR', 'Blanking off the EGR', 'Disabling the EGR' etc.. and still can't anything specific apart from discussions about it. I've found it mentioned that there are photos on here and loads of info but no links and I can't seem to find them myself. Is everyone privvy to it but me? I'm starting to get paranoid

[Doone]

Did you look at all the links within the links here: http://www.igmaynard.co.uk/bongo/forum/ ... &sk=t&sd=a There are plenty of photos.

[jaylee]

LOL - the leaf in the fuel tank! Someone did mention a senario with gunk in the fuel tank too - maybe it's something I'll check out. My list of processes to eliminate keeps getting bigger!
I've just noticed that my Bongo is one set up for a cold weather climate - two batteries and a valve mid-way through the exhaust system. I'm not sure if this has any bearing on it.
Whereabouts do you block off the EGR at the rear? Is it underneath the EGR valve? I'm not sure yet as I've not had it apart and the illustrations in my manual are a bit open to interpretation.

I wouldn't discount it..!
Might turn out to be a simple cheap fix...?
Good luck!

I've had an intermitant problem with my Bongo for about 5 months - stalling on idle when hot. It takes about half an hour of driving before it does this (and sometimes it doesn't do it at all!).Also, it's a bugger to start once stalled and takes about 15 seconds. It's been in 3 garages now (2 diesel specialists) - had the fuel lines pressure testing (fine) fuel and banjo filter replaced. Everyone has agreed it's a problem with the fuel getting through and one was convinced it was the pump (he said it would cost me a fortune to rebuild/replace)
Stew on here had a similar problem and eventually fixed it through a combination of EGR blanking, vacuum hose replacing and relocating and the addition of a fuel pump/primer.
I'm gonna start with the EGR blanking as it seems the easiest and seems to have benefits anyway. I've trawled the site here several times under loads of searches and can't seem to find any specifics. I've got the manual and located the EGR pipe running over the drivers side of the engine. It seems obvious where to blank off the front end of this at the gasket but I'm not sure about the other side (and I don't want to blank of the wrong pipe!)
It's my only vehicle at the moment and I'm hoping to drive up to Edinburgh tomorrow night.
Any help would be appreciated

[bongomaan]

if you get an egr blanking kit from allans (website on fury homepage) cheap £12.00 and easy to follow instructions. I have a similar(ish) problem and egr blanking did not solve it but did improve smoking and emissions and defiantly improved performance. So when my tank runs low, off its going to come and i shall give it a clean. By the way my symptoms are van is fine for short runs but after a run of 30 odd miles it sometimes stalls but i always have probs starting again as though its starved of fuel, all filters aok, anyway good luck to us all...












0

[Mel Holmes]

Thanks for all the help guys and thanks for the link Doone. Couldn't seem to find those posts through my searches.

After checking throught the EGR system it appears that it has already been disabled by the removal and capping off of the vacuum pipe! I guess it must have been done in Japan as it had only been in the UK a month or so when I bought it. (I was a little bit miffed as I was hoping to get a slight mpg improvement by the modification - it's pretty bad at the moment)

Best start investigating the fuel tank for foliage

[Simon Jones]

...van is fine for short runs but after a run of 30 odd miles it sometimes stalls but i always have probs starting again as though its starved of fuel,all filters aok

Just a thought - have you tried removing the fuel filler cap to see if you get a great rush of air? I have seen a car where the vent / breather was blocked so after a short distance the vacuum in the tank was greater than the suck of the pump & therefore it was started of fuel.

[scanner]

Just because the vacuum pipe has been disconnected doesn't mean the EGR has been disabled - only it's operation has been disabled.

If it is stuck open (not uncommon) it is stuck open whether the vacuum pipe is disconnected or not.

The only sure blank off is the plate in the inlet manifold end joint method as achieved with the "Allan's" kit..

[bongomaan]

cheers simon,off to symons yat tomorrow that should bring it on and i"ll try that,i did speak to a very nice aa man about it and according to him there is no vent/breather in the filler cap after such and such a date because of eec rules on fumes,i did try to explain obviously its Japanese but he didnt seem to listen according to him there is a carbon filter somewhere.at the time the thought occurred to me to drill a hole in the filler cap but i got distracted by the gearbox packing up and never got back to it,ishall look at it again,cheers... UPDATE..went to symonds yat filler cap trick worked for me will drill a hole in it tomorrow ..cheers simon

[Mel Holmes]

Simon - I've tried keeping the filler cap off but it doesn't seem to make any difference. It would be a nice easy fix though

Scanner - Yes, I think I'd better blank off the EGR anyway to be on the safe side

[bongomaan]

hi mel if you go for allans kit one bit of advise i would offer,it may not make sense till you get it but at the back of the engine compartment there is a gold colored plate removing this will help you,it doesnt take long to fit this kit and is time and money well spent,any other help give us a shout..

[mister munkey]

I've just noticed that my Bongo is one set up for a cold weather climate - two batteries and a valve mid-way through the exhaust system. I'm not sure if this has any bearing on it.

I had the same symptoms a while back, running like a lumpy bag of nails. An obvious check that I missed for a few days earlier in the year was the Cold Starting switch was on (Thanx again to Waycar8!)

Brilliant feeling when you go from thinking you have to spend hundreds to just flicking a switch instead!

Have a look, y'never know . . . .