Bongo Fury

Im really fed up with a fault on my van. Its a late 1999 AFT with 60k (miles) on the clock. It has a flashing glow plug light and originally this came on once the van was up to operating temperature 15mins into a journey and at this point I would get no turbo.

I changed the Vacuum valve and removed the wastegate gasket. This had no effect at all, the garage stated that they couldnt get a fault code indication on their machine, eventually after numerous different machines they got
2 faults, 1. PO400 EGR system flow malfunction and 2. P1228 wastegate failed open under pressure. They checked the EGR which was all gunked up and was cleaned they also changed the actuator on the turbo as it was worn and very loose. They also added a diesel engine treatment to try and decoke the system.
After all this and numerous weeks at the garage the light is still coming on all be it a little later the garage state that there is no loss of power when the light comes on?

Any ideas? Garage say they are stumped. I'm fed up and want rid of it now no confidence anymore in what was my pride and joy.

Any help would be much appreciated.

KARL

Have they re-read the code now?? there's no way you CANT get loss of power if your still getting the same codes, the only other thing i've seen do this was when some1 started messing about with the pipes that connected to the 4 valves under the divers seat, check they havent got the egr vacuum pipes reversed, the lower of the 2 egr valves should go the rear most valve, if you get stuck let me know and i'll take a pic of them
julian

I'll check with the garage thanks

321Away wrote:Have they re-read the code now?? there's no way you CANT get loss of power if your still getting the same codes, the only other thing i've seen do this was when some1 started messing about with the pipes that connected to the 4 valves under the divers seat, check they havent got the egr vacuum pipes reversed, the lower of the 2 egr valves should go the rear most valve, if you get stuck let me know and i'll take a pic of them
julian

Garage say the fault codes are the same but there is no loss of power since the actuator was changed? Im not sure what to do next! The garage dont know either!!!

This has been brought up in the past and I can't remember who it was. Similar symptoms to yours - I guess you have a fly by wire fuel pump??

It could be a long search, but you'll find an ansewer in the search facility unless someone remembers the post.

Out of curiosity, why did you remove the wastegate gasket??

This one you mean Dandy? - http://www.igmaynard.co.uk/bongo/forum/ ... 15#p494615

missfixit70 wrote:This one you mean Dandy? - http://www.igmaynard.co.uk/bongo/forum/ ... 15#p494615

That'll be it mizzie - I see your taking your signature seriously.....................

Always have been good at producing fantastic amounts of BS

I quite like yer new animated avatar Kirsty..

Sure they havent piped something up wrong, if your getting a 1228 thats wastegate failure to open, and your turbo wont be spooling so its impossible not to have power loss, check they havent been crafty and swapped the pipes on the little atmospheric referance unit (rail next to the turbo, 1 plug,2 small pipes going vertically onto it) in which case it slams the wastegate full against the closed stops, and the ecu will see a fault as the boost sensor wont see rising/falling boost vacuum

dandywarhol wrote:This has been brought up in the past and I can't remember who it was. Similar symptoms to yours - I guess you have a fly by wire fuel pump??

It could be a long search, but you'll find an ansewer in the search facility unless someone remembers the post.

Out of curiosity, why did you remove the wastegate gasket??

Have you ever seen a new shape wastgate? its nothing like i've seen before and i was with MOD for 12 years and a well known F1 team for a year, the wastegate works on a rotational motion, between it and the wall is a steel multi-layer gasket, when the gasket gets old due to heating/cooling, it seperates and once it warms up it puts pressure on the face of the wastgate which means the louvres cant pivot and requires extra pressure to open/close the wastegate, which maybe a factor in the vacuum valve burning itself out, which in turn also stops the EGR, causing the 0400 fault, i've got some pics will post them later

Julian

321Away wrote:Sure they havent piped something up wrong, if your getting a 1228 thats wastegate failure to open, and your turbo wont be spooling so its impossible not to have power loss, check they havent been crafty and swapped the pipes on the little atmospheric referance unit (rail next to the turbo, 1 plug,2 small pipes going vertically onto it) in which case it slams the wastegate full against the closed stops, and the ecu will see a fault as the boost sensor wont see rising/falling boost vacuum

dandywarhol wrote:This has been brought up in the past and I can't remember who it was. Similar symptoms to yours - I guess you have a fly by wire fuel pump??

It could be a long search, but you'll find an ansewer in the search facility unless someone remembers the post.

Out of curiosity, why did you remove the wastegate gasket??

Have you ever seen a new shape wastgate? its nothing like i've seen before and i was with MOD for 12 years and a well known F1 team for a year, the wastegate works on a rotational motion, between it and the wall is a steel multi-layer gasket, when the gasket gets old due to heating/cooling, it seperates and once it warms up it puts pressure on the face of the wastgate which means the louvres cant pivot and requires extra pressure to open/close the wastegate, which maybe a factor in the vacuum valve burning itself out, which in turn also stops the EGR, causing the 0400 fault, i've got some pics will post them later

Julian

Thanks Julian,

I will check when I get the van back, the garage are stumped they have not seen this problem before however have not worked on many newer shaped models. Am getting the van back as they are indicating there is nothing else they can do, might have to make a trip south to see if you can sort it. I have friends close by!!

Am really hacked off making me wonder why I didnt go for a VW T5 like my pal.

missfixit70 wrote:This one you mean Dandy? - http://www.igmaynard.co.uk/bongo/forum/ ... 15#p494615

Thanks for the link to the thread, appears to be the same symptoms, after reading the 11 pages I am totally confused! Not sure what my next move is. Getting the van back in the next few days not sure if there is anyone north of the border with the experience to sort out this gremlin. Looks like I won't be getting away in the van this season! The kids will be be pleased.......NOT!

Sorry to hear you are having problems. May be worth giving Bill a call at Campercraft.....(Campercraft. Unit 5 MUIRHEAD ENTERPRISE COURT MITCHELSTON INDUSTRIAL ESTATE, Kirkcaldy, Fife KY1 3LN. p: 07907661175 )

Thats where it has been for the last 7 weeks or so Bill is fed up with it as am I and his mechanics are stumped by the faults!

Welshcav wrote:Thats where it has been for the last 7 weeks or so Bill is fed up with it as am I and his mechanics are stumped by the faults!

My apologies.... Bill did mention that he had been wracking his brains to find out what the problem could be with a van he was trying to fix when we saw him at the Scottish Bash. I did'nt put two and two together There is a garage in Duff St lane, Edinburgh who are fairly bongo savey as well. May be worth doing a quick search for their number.

All the best

David.