Bongo Fury

Hi all I finally got around to chancing the rocker cover gasket tonight and when I was reassembling everything i noticed a small split in a little black tube, in the picture it's the one with red tape on, it connects to one side of a little plastic t piece at the side of the rocker cover. Does anyone know what it does and should I replace it?

the T piece is on the rear of the cold start solenoids, the pipe is the vac supply to the egr solenoids, these actually control the vac to operate the egr valve itself. the egr has a position sensor on it, it sends a message to the ecu, when the inlet manifold suction pressure overcomes the little green valve the vac is lost. this system should be intact for the system to operate correctly. some have removed parts of the egr control system controls with no ill effects but i would recommend leaving it intact as it is linked to the ecu even if the egr is blanked off physically especially on the later pump/turbo model.


if yours is an early diesel the part your interested is marked V in this link. it connects to the valve also marked with a V.

http://lushprojects.com/bongopartsmk2/c ... 1of02.html

short answer -------yes, with proper thick walled vac pipe.

the throttle cable securing block clips into the square hole in the pic, mind you dont break the airpipes though.

Thanks NB,

Yes mine is an early 95 bongo with winter pack and short section exhaust, I don't think the EGR has been blanked off, I noticed all the vac pipes have gone hard at the ends or were they made like this? I wouldn't have thought so prob due to age,heat etc.

Anyway I taped the small split up and I will replace it when I get around to it but for now it's all back together and working fine.

On a separate point there was far more oil on the block than I thought, there was definitely a problem with the rocker gasket which hopefully is now solved but I can't believe it's travelled all the way down the back towards the gearbox, I don't think there is any oil coming from the crank shaft oil seal as this looked ok, it is mainly the middle and back of the engine block

The last 3 MOT advisories were "oil leak" but I've hardly needed to top the oil up during oil changes so it's not really concerned me, hopefully this is the only leak, I guess time will tell.

the engine is tilted backwards slightly to align with the rear axle, any leak from the rocker gasket goes towards the gearbox front.
the rocker cover gasket is not just as straight forward as in the old days, it has bolts with rubber type sealing washers, steel washers, and compress tubes down through the gasket. the bolts need to be tightened to a very light specific torque setting, too loose and it will leak, too tight and the tubes squash out of shape and leak, new gasket and tubes and top sealing washers is the only way without resorting to gunk sealer.

the ends of the vac pipes should not be age hardened but most are, best to replace them but BE VERY CAREFUL not to snap off any ports on the solenoids as these are equally as old and brittle. if you use inferior grade pipe they may suck flat when hot and not let vac through.

Good advice NB

It's no good Northern Bongolow, I had to strip it down again, I wasn't happy with leaving the vacuum pipe taped up, so took the tube to local motor factors, they had a slightly bigger external diameter tube but it had the same internal diameter, so I changed all the vacuum tubes. The one that connects from the TPiece through one of the injectors and to a metal pipe under the drivers seat was a real pig...no room to access so I had to remove the air filter housing and attack it from that side. I feel happier they are all done as they were extremely brittle and hard and when I bent them after removal they just snapped so it was only a matter of time before they failed.

I also took the time to nip up the rocker bolts to 8.8nM as per NB's post a few months ago.

What would I do without you guys on here.....amazing help....thanks again.

And yes I did remember to relocate the throttle cable support before I put it all back together (only just )