Bongo Fury

So benji was doing very well for his first year but alas he is struggling.

Three months ago I had a diesel leak - traced to a o-ring in diesel pumps replaced and running fine.
Five weeks ago he was slow to start - had my glow plugs all replaced and injector cleaner put through. Been fine since.
Two days ago, it started fine at 5 am on a cold morning. I stopped to fill with diesel, and it was then slow to start up (and yes, I definitely put diesel in). Drove for 2 hours and it was fine. But 10 hours later it wouldn't start - turns over but no firing. Sprayed easy start, and it starts and then drives fine. Park up for more than 3 hours and it won't start again. No noticeable diesel leak.

Can't get in at any garages that folk around here recommend and awkward as I'm working and sleeping away in it this week so can't let it go to a garage overnight as I need to sleep in it! And being bank holiday it is rubbish timing.

Various thoughts are dodgy fuel as happened immediately after filling up, or small hole/leak from somewhere in the fuel lines.

Any thoughts from bongo techies? Anything I can investigate myself.

We seem to be getting a few of these. Sounds fuel feed related, advice is generally to start with the simplest and move on from there:

* Try loosening / removing filler cap to see if cap breather is blocked
* Check/replace fuel filter if not done recently in case there's a blockage/obstruction there
* Check / clean banjo filter in case its got blocked/obstructed.
* Check for leaks in fuel pump, though if the leak is causing air to get into system then you may not see any dripping
* Check fuel lines to see if fuel is pulling through OK
* Phone a diesel specialist to see if they might look at it.
* Read all the old threads on here.

Hope you get it sorted soon - keep us posted

Long shot, but the garage may have been delivered wrong or contaminated fuel.

Any reports of others having problems after filling at the same place?

rig up a temp supply of fuel, small container linked into the fuel pump inlet pipe to eliminate the tank and filter side of things and poss bad fuel.

Northern Bongolow wrote:rig up a temp supply of fuel, small container linked into the fuel pump inlet pipe to eliminate the tank and filter side of things and poss bad fuel.

Won't necessarily eliminate possibility that air getting pulled into pump while car at rest (due to faulty seal) could be allowing fuel to fall back into tank creating airlock in fuel line?

Benji , it would be worthwhile checking to make sure that power is reaching the Glow plugs/ rail, and the glow plugs are working.

Sounds a little like air getting into the system somewhere, to me.
I would try bleeding it right up to the injectors - take an injector pipe off after you've bled up to the pump - and then try and start him, obviously without easistart though. If you have air in the system a few hours after a drive, there's your starting point....

Just a thought

Edit

Has anyone mentioned the fuel filler cap yet? Make sure the cap is venting properly to allow the fuel to be drawn out from the tank to the engine - initially just take the cap off perhaps?

Well, a few weeks on - due to me having flu!!! Benji is in the garage and they are saying that it is the diesel pump leaking again. I had one o-ring replaced by a different garage at the end of last year. They are recommending replacing with a 12 month guaranteed pump at £600 plus vat plus labour - total bill £1008!!!! Ouch!!!! They said they have a couple of second hand ones which would have a month guarantee - around £300 plus vat.

Do these prices seem reasonable? Seems a tremendous amount to me but I need Benji to be reliable.

PS Having a great dilemma as to whether it is worth spending £1080 on Benji being that the vehicle only cost me £1795 in the first place as it is old and a tin top. I contacted the conversion company and they would strip out and refit a new bongo for only £500.

Should I therefore be buying a more reliable vehicle or better the devil you know/labour of love etc!!!! Your thoughts are most welcome please.

Seems steep but quite possible especially if the garage is not familiar with the job. If my sums are right, you are being charged about £250+VAT labour which equates to 3-5 hrs work depending on their hourly rate. 3-4 hours is probably about right for somebody unfamiliar with the job - I was quoted similar amounts by my local non-bongo independent. To put this in context George at Bongospares claims to remove a fuel pump in 30 mins! I think my local Bongo specialist charges about 2 hours to remove and replace.

Bongospares may be your best bet for a replacement pump. Used to be around £400+VAT for a refurb unit.

If you send your old pump away to have it refurb by an injection specialist it will cost that and more though I suspect you get a more in-depth job done but since it is usually just the seals we're bothered about it is probably overkill. And you have the inconvenience of your van being off the road.

The cheapest option would be to find a Bongo specialist who replaces the seals in house (like ADS or Bongospares).

Benji wrote:PS Having a great dilemma as to whether it is worth spending £1080 on Benji being that the vehicle only cost me £1795 in the first place as it is old and a tin top. I contacted the conversion company and they would strip out and refit a new bongo for only £500.

Should I therefore be buying a more reliable vehicle or better the devil you know/labour of love etc!!!! Your thoughts are most welcome please.

Depends entirely on the condition of the vehicle.

If this is your only major cost to keep it running for a year then I'd consider it worthwhile. Fuel pump seals fail on these, its not exceptional, though one of the most expensive single items (cracked heads aside). If you have serious doubts about other aspects, then you may have a point. Important thing is whilst it is a runner, you have zero depreciation. Your only cost is what you spend on keeping it running. My view, for a 20 year old vehicle that gets used, if that cost is <£1k / year then I'm ok.