Bongo Fury

hi all

I brought my bongo nearly a month a go specifically for a 3 month tour of Europe my girlfriend and i plan to do next year. The idea is to make the bongo mechanically sound in the next 6 months, improve the existing rear conversion with better bed, fridge and more storage space and then tell my boss what to do with his job (politely of course) and take off.

So far i have used the members fact sheets to do the oil and filter change, fuel and air filter, coolant drain flush and refill. I also had to change the glow plugs as 1 hour after purchasing my bongo it would not start so after trawling the forum and bongo clinic for an evening i deduced that it must be the glow plugs, sure enough 1 plug had completely failed and 2 more were very slow to heat up so i changed all 4. When changing the plugs i noticed that there was a small leak on the first diesel injector (working left to right) this does not cause a problem to the running of the engine it runs very well but i want to get it sorted.there appears to be not much mentioned on the forum with regard to injectors so i was hoping the more experianced of you bongoers would be able to advise me on what to do.

all advise/ experiances welcome.
thanks
adam

Adam, I am your boss - your FIRED!!

Seriously, enjoy your Bongo, I am sure you will have a great trip.

We went to the French Pyrenees this summer, others have done even longer distances to the extremities of Europe, all with no bother at all.

Take any diesel leak seriously.
The injector consists of 9 parts, two of these are the top and bottom 'container' for the valves working parts.
Two spanners, and tighten the blighter (Two spanners so you do not tighten it into the block.
It would be wise to remove it from the block first. Make life easier if it is on the bench.
The manual shows how to disassemble the injector, but without a high pressure test pump you would not know if the spring was OK.
Valve 'let by' pressure is 120kgf/cm2 new, 110kgf/cm2 used
It should not leak at 90kgf/cm2, if it does then it is either a weak spring or dirt in the valve assembly.
I recommend you buy a copy of the workshop manual and wiring diagrams CD from Ian of Bongo Towers, it is expensive, but would be an invaluable addition to your 'tool kit', and could save you loads in the event of a breakdown.
Good luck with your adventure.

hi

Thanks for the replys pippin and will, sorry i have not replyed sooner only with work, christmas, lack of natural light and every thing else i have struggled to find time to look at the injectors. However i have now and its not the injector its self but the drain/leak off pipe that returns excess diesel from each injector to the pump.(not sure of tech term )So has any one an idea of where i can get this part i have looked on the usual suspects web sites but its not listed. Failing that i thought about trying to solder the leak(when its disconnected from engine and fuel supply) would this work
Again all thoughts/ideas welcome.

merry christmas all
Adam