Bongo Fury

Hi,
I have posted a few times my problem but can not find any solution.
I am so fedup with the thing I just want to give up and crush the bloody thing.

1996 2.5TD Bongo Auto

The problem is no low down power, struggles to rev from idle to 2000rpm even to the point where i can put it into reverse and have my foot flat to the floor an it will not move. Struggle to pull away from junctions etc
Once the turbo has kicks in its has power just anything below 2000rpm it just about pulls itself.

I have tried/replaced the following -
Brand New Fuel Filter
Small Banjo Filter in Pump
All Vaccum Lines
Blanked EGR
Brand New Injectors
Brand New Glow Plugs
Replaced all the Auto Box Fluid New (On flat ground running etc)

Can someone help. I have a spare engine and even tempted to just put that in as i am that fedup with this one.


HELPPPP

on the side of the turbo is the waste gate diaphragm, its the drum shaped thing with a rod on it, this operates the wate gate inside the turbo. see if this is working.
you can split the turbo in half to check the internals are working.

has the fuel pump got a fuel leak, low down at each side, look when you rev it, then let your foot off,it may leak when coming off the throttle. this is the throttle advance side seals, it maybe its sucking air instead of fuel.

Replaced the waste gate off my spare engine.
No fuel leak anywhere.

I have just fully rebuilt my spare pump with is my next step but thinking I am going to fully rebuild my spare engine an just install that.

Where are you based?

Beardy, on 27th Jan 2011 you posted this:

Just seeing if anyone else has had this problem.

Driving along in my 2.5TD an all of a sudden lost power, she would not rev over 2000rpm.
Bongo was given a full service 3 day prev's.
Found the problem to be a lack of fuel to the engine.
After alot of searching/fault finding i found the problem to be the fuel filter.
Inside the fuel filter there is a spring system which works with pressure and on the new patten part the spring system had jammed.
Replaced with old filter and she ran perfect, problem solved......

Anyone know is this a problem common? what fuel filters to people use? genuine part only?


Sounds very similar to your current problem. How long did that 'fix' work for?

Might be worthwhile having a wee look at the inside of the fuel tank or fit a test bottle (after the fuel filter) to eliminate the tank/filter housing and suction line.

running from the air inlet manifold to the top of the fuel pump is a 10mm dia pipe, this is a vac pipe,this pipe works the diaphragm on the top of the fuel pump. ive seen a few that are totally full of oil in the diaphragm so acceleration is affected quite badly.

i use only good branded fuel filters, some of the internals of the cheap ones are crap. mann filters.

Tried 3 brands of fuel filter all over a space of 2 weeks.
I have removed said pipe as I read in a earlier post, cleaned checked etc
Tank removed, drained inc presuring the lines for leaks

I will add out of gear she will rev free as a bird

I am in Oldham, Manchester

Binding brakes?

teenmal wrote: fit a test bottle (after the fuel filter) to eliminate the tank/filter housing and suction line.

Yep back to basic fault finding makes more sense than throwing money at parts and never change more than one part at a time.

Is the timing ok?.

First step let's check timing, 2nd test tank fuel as previously said with pipe into cont bypassing tank,third drive with fuel cap off,is there a lot of black smoke ie air intake blocked?presume it was timed ok when pump was refitted?put a pipe straight onto pump from test tank,keep fuel cap off in case the tank isn't breathing you won't need to do this if you're running a test tank .goid luck and let's hope between us all you'll get it sorted

BeArDy wrote:Tried 3 brands of fuel filter all over a space of 2 weeks.
I have removed said pipe as I read in a earlier post, cleaned checked etc
Tank removed, drained inc presuring the lines for leaks

I will add out of gear she will rev free as a bird

I am in Oldham, Manchester

You're not far from Adrian at Japandirect in Bury. He knows Bongos+++ and his prices are good. Could give him a call if all else fails? He's excellent to deal with Good luck, keep us posted.

Northern Bongolow wrote:on the side of the turbo is the waste gate diaphragm, its the drum shaped thing with a rod on it, this operates the wate gate inside the turbo. see if this is working.

Out of interest, what sort of revs has the engine got to be doing for this to operate?

I'm not convinced that mine ever moves. I had the passenger seat up today checking the oil. I always run the dipstick past the actuating rod to give it some lube and having recently read this thread, decided to give it some revs to see if it moves. It didn't at any revs I would normally subject my motor to. Or won't it do anything unless there's a load?

I've never been convinced that my turbo does anything spectacular. I've always been intrigued at mentions of it cutting in at certain revs. I guess if it didn't work, the Bongo would have no guts. I think I would have noticed that by now.


Frank

The wastegate is there as a safety valve to dump excess boost and prevent the engine from revving itself to death.
So if you think your turbo isn't working it can only be the wastegate if that is stuck in the open position.