Blanked off my EGR today and also replaced the gasket in the inlet manifold (manifold to curved inlet pipe). Very easy to do apart from one nut on the rear end of the EGR pipe which was a complete sod to undo - very shallow nut which sockets found difficult to grip once the corners were rounded off.
The EGR pipe was nearly completely blocked.
But also noticed some black sludge running down the engine block from around the front end of the inlet manifold at the position of the first pair of bolts. I thought initially it was from the joint that I had just attended to, but I think its a leaking inlet manifold gasket. None of the inlet manifols bolts were loose. But slackened and retightened the 2 front bolts anyway. What is the torque setting for these bolts ? about 25Nm maybe - certainly not high.
Are there any issues I need to be aware of if a go ahead and replace the inlet manifold gasket?
Where to get the gasket from ?
I think the injector pipes and EGR pipe will need to be removed in order to free up the manifold but little else needs to come off as far as I can see.
Do the lnjector pipes require new washers or anything on refitting ?
Leaking inlet manifold
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Jules59
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Alacrity
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Re: Leaking inlet manifold
I have the same leak on mine, I will watch this thread with interest.
35+ years working with autogearboxes - all day every day......for my sins
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missfixit70
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Re: Leaking inlet manifold
I think just about every diesel bongo has the same leak 
You can't polish a turd - but you can roll it in glitter.
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Jules59
Re: Leaking inlet manifold
what do most people do about it ?missfixit70 wrote:I think just about every diesel bongo has the same leak
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missfixit70
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Re: Leaking inlet manifold
Clean it off once in a while or leave it?
You can't polish a turd - but you can roll it in glitter.
Re: Leaking inlet manifold
Mine had the leak, sorted recently. Most don't worry about it, until serious oil loss starts.a leaking inlet manifold gasket
Servicing Bongos since 2003 in Plymouth, Devon http://www.allansvehicleservices.co.uk
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Jules59
Re: Leaking inlet manifold
How exactly did you sort it ?Allans wrote:Mine had the leak, sorted recently. Most don't worry about it, until serious oil loss starts.a leaking inlet manifold gasket
Did you do it yourself ? If so then maybe you could answer my questions from my opening post.
ie
What is the torque setting for these bolts ?
Are there any issues I need to be aware of if a go ahead and replace the inlet manifold gasket?
Where to get the gasket from ?
Do the lnjector pipes require new washers or anything on refitting ?