To quote Scanner: "It is accelerating back up to speed again after a stop that really kills MPG."
This is very true and the more slow and smooth you accelerate the better. (Not always practical with a bright white LED Merc impatient revving up behind you !)
To drive economically actually takes a bit of practice. A good rule of thumb is the more you are pushing the pedal the more fuel you are using. Be mindful of that, gently does it. Around town is not going to provide good mileage in a Bongo mine is pretty dire too, I have never measured it though as I do not do much in the way of local journeys. i.e., short 5 mile ones.
I listen to my engine, high revs = more consumption, be smooth accelerating, reading the road ahead to not brake when it is not necessary.
When I am up to speed on a motorway I listen to my engine sound, there is a speed around 50mph-55mph where there is this sweet spot where the engine/gearbox makes minimum noise, this must mean minimum friction and a mechanical balance/equilibrium. THIS IS THE ECOSPOT !
Try and reside in this smooth state for as long as possible on a big A road or M way. It is almost like a point where there is a perfect balance of revs vs momentum or throttle depression vs speed. That's the only way I can explain it.
Of course you cannot sit there forever as there are of course inclines / road events but you judge these in advance from watching the road and make smooth relaxed compensations on the throttle minimizing the need for abrupt speed changes.
Pull out things I do not need to carry about, tyre pressures (tyre types), no aircon or windows open at relevant times, always empty water tank when not going to be used. Above all think :
SMOOTH
I feel like a broken record sometimes but :
Given the amount you are spending on diesel it could well be worth trying:
1 Can of BG244 in your diesel tank ( a 1 use per year cleaner)
http://www.amazon.co.uk/BG244-DIESEL-FU ... B0062KYGZC
BG 244: Fuel System Cleaner designed for Diesel £21.99 on Ebay
And then add Millers diesel Power Ecomax additive to subsequent tanks (you can put a double dose in as well as per instructions if you wish) after that (Millers is a regular use diesel fuel additive/cetane booster and fuel line/injector/lubricant/ cleaner)
http://www.millersoils.co.uk/automotive ... sector=Car
http://www.ebay.co.uk/itm/Millers-Diese ... Sw8-tWVY4d
Unless my meter is inaccurate (and I have checked my mileage on google and it adds up correct as per the meter and my calcs within an acceptable couple of miles) I can with regularity get 40MPG on a 50-55mph (I can get high 30's even when stuck in jams for hours) run so getting only 27MPG which is about 35pct less seems a bit odd. I did my 43mpg record down the A303 going west from the M25. I do a rough calc using brim technique every now and then and 40mpg is pretty much standard on a long run.
(Did you do air filter as well? That's a fuel economy biggy)
People on seem to achieve 27-35mpg on long runs from what I have read.
I don't know if mileage (or km-age in the case of a Bongo makes a very big difference) but mine has only done 148,000kms - 91,000 miles. That could well be going in it's favour as that is very low mileage for it's 20 year age and the engine will not have worn that much as long as the servicing has been ok.
I have to say I rate the products I have mentioned above highly. Both the one off/occasional use BG244 diesel fuel system cleaner and the Millers. It cleans any deposits from the fuel lines, injectors, intakes, valves etc. and as I gather these deposits can right royally screw fuel efficiency and power up.
How many miles has yours done ? If it has never had a BG244 then that really must be worth a go. FWIW other than the rare problem start I have had which has not been seen for a long while) My exhaust to the eye is clear as air itself. No soot at all, nothing, even after just 2 mins idle when it is not warmed up even. I think I got a good engine.
They call me light foot.