unclipped drivers seat discovered oil around engine

[bikerbob]

Having unclipped the drivers seat to check the power steering bottle level which appeared to ok but found oil spray all around the area and oil dripped down to under the wheel arch, thought it was a leak from bottle however having cleaned up the bottle & air filter housing & cylinder block water hose, discovered what appears to be a fixing for a hose!! from an aluminium manifold type thingy. The fixing is on a alloy 2"circular tube which is then fixxed to a plastic hose and is to the front of the timing belt cover.this appears to be the source of oil spraying over every where as it is pointing outwards directly towards the power steering bottle etc.
What is it? should there be a hose fitted to it?and where does the tube go to?
Also the power steering fluid is black & oily is this OK?

I am dreading investigating further areas of the Bongo and finding other issues, thought I was a smart ass buying vehicle in a private deal at a reasonable price from an aquaintence, believe he was not aware of the issues as he had the vehicle serviced last year and he had only done 1800 miles since.

[bikerbob]

As the silence is deafening on information from the forum I contacted the supplier of the vehicle and described the problem to the mechanic, without him actually viewing the area described he suggests it may be a vacuum boost hose that should connect from the manifold onto the diesel pump wherever that is!!! he was fairly vague on the subject as he said he had not worked on a Bongo for some time(Garage is on the BF good garage guide) if this is so could the re-connection of this hose give an increase in performance? - any enlightment from your good selves on this theory would be welcome.

I also asked if it would be ok to fit a hose onto the manifold outlet and then into a collecting bottle so the `oil`would not be p...ing out` whoops `sorry, contaminating the engine area, it was confirmed as being ok to do so. The vehicle was supplied by this garage over 4 years ago and I wonder if this hose was missing then, although in mitigation it has been serviced by two seperate garages since and not spotted. I was going to have the vehicle serviced at the garage last used by the previous owner but not confident they know the servicing procedures & health checks for a Bongo, so a search will be on to find a local Bongo friendly garage but I will be armed with the BF service fact sheets.
TTFN

Bob

[wonkanoby]

are you sure its oil

http://www.igmaynard.co.uk/bongo/forum/ ... boost+hose

as this one would spray diesel

[borntobag]

"discovered what appears to be a fixing for a hose!! from an aluminium manifold type thingy"

could this be the reminants of an EGR valve removal? which is the normal culprit for black gunky oil on that side of the engine?

[roofraisers]

The alloy thing that you are looking at is the air inlet manifold for the engine.
A large diameter (about 60mm) black pipe should be connected to the front of this with a jubilee clip. This pipe then goes down to the intercooler on the front of your Bongo underneath the radiator.
On the side of the manifold,just above the jubilee clip there is a small diameter pipe (about 8 mm). That should be joined to the top of the fuel injection pump with some flexible vacuum hose. The spigot on the injector pump is located just above the throttle cable connection (possibly slightly hidden by some electrical wires & connectors on top of the pump).
If you look at the injector pump with your eye line over the power steering resovoir you should see it.
The vacuum hose is held on at each end with a spring clamp.

There are then some other bolted flanges that are to do with the EGR system, but I don't think they are causing you an issue.

Hope this helps.

Nigel.

[jaylee]

discovered what appears to be a fixing for a hose!! from an aluminium manifold type thingy. The fixing is on a alloy 2"circular tube which is then fixxed to a plastic hose and is to the front of the timing belt cover.this appears to be the source of oil spraying over every where as it is pointing outwards directly towards the power steering bottle etc.
What is it?

Not this perchance...?



If so it heads here...



I don't know a lot about this sort of thing (If it is??) it should not be spitting oil..!!? I wager the inter cooler may be full of oil too?

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

[roofraisers]

Them's the pic's.
I have to agree, there shouldn't be alot of oil blowing out of that hole, maybe a bit of a misting, but if the intercooler is full of oil it's going to want taking off & emptying out.
On the up side if this is the problem.... we know the turbo is working OK.

Nigel

[jaylee]

Quick note.



Ignore the tee piece on the vacuum hose bottom mid picture.... Not OEM. One of my mods to a turbo gauge!!

[bikerbob]

Gentlemen you have cracked it, the pics show the missing hose but not clear where it actually connects to at to`ther end can you identify more clearer what it should be connected to it seem to disappear into the engine area.cannot go out & check as the vehicle is at another location at present & will be bringing it home tommorrow. What hose & clips do I ask for & where can I get them from.

Regarding draining the intercooler is there anything in the forum or a fact sheet, have been trawling through both but have not as yet found anything , is it critical to empty it & what benefit will it have on engine performance etc
Thanks for you patience And I`m sure there will be more `senior moments to contend with.

Regards Bob

[roofraisers]

If you crouch down inside the open drivers door & look at the injection pump with your eye level above & then look over the top of the power steering pump.
You should see a metal spigot coming off the upper square part of the injection pump. This is what the vacuum hose connects too.
I would have thought any motor factors would have hose that you require, or failing that go to a garage that does diesel engines even a HGV workshop would have suitable hose as all pump/ turbo pipes are similar diameter. You will need a length about 250- 300mm long with suitable clips. Once fitted, trim to a nice length so it doesn't catch or rub too much on other things.
Hopefully I have found a link that has a suitable photo for you as well.

As for the Intercooler, I've never taken one off a Bongo.
It's generally just a case of disconnecting the air in/air out pipes & then removing the few nuts & bolts that attach it to the Bongo.
I notice in another thread you may be fitting a radiator. The intercooler could be done at the same time as you will have a bit more space & see a bit more easily what you are doing.
If too much oil is in the intercooler, you are interfering with the air flow to the inlet manifold from the turbo.
You are probably decreasing the efficiency of the intercooler & if excess oil gets blown up to the engine with the charged air, you will notice blue smoke coming out the exhaust pipe.
It would be a job thats probably worth doing if a lot of oil is being blown about.
Just take the intercooler off the Bongo & place in a suitable container to collect the oil as it drains out.
It might be worth noting & then posting back up here, how much oil you do get out of it as other owners may be interested.

http://www.igmaynard.co.uk/bongo/forum/ ... 00#p117600

Nigel.

[bikerbob]

Thanks Nigel the information & link you gave is very informative, would never have picked it up on the forum, perhaps that is a reason while the Bongo`s get up & go has gone, will try to work on it tommorrow and post how I got on but have to prepare for my 5 day motorbiking holiday touring in the Lake district & Yorkshire dales starting friday. See You`ll if I survive.

Regards Bob.
AKA Bonneville 865 Bob

[jaylee]

Inter-cooler; i don't claim to have the most finely tuned Bongo on the forum.. But here is what i found when changing mine after a tangle with a fox mangled the air scoop too...

http://lushprojects.com/bongopartsmk2/c ... mgno=.html

3 nuts at the back to the chassis...



Surprisingly clean inside..




I also found my vacuum hose split while i was modding the turbo gauge so replaced the length from a local motor parts shop with a similar diameter, but slightly thicker wall hose & used what was left over from the tee piece to the gauge sensor..



Another vacuum hose comes off the back of the pump..



Then runs up to the solenoids or the cold start & AC on idle control..



I would imagine your idle also dropped noticeably when the AC is switched on, as well as on the "cold start" without this vacuum hose attached???!!


Hope this helps?

[borntobag]

A word of warning from experience, if you empty the intercooler of any excess oil and gunk, dont be tempted to clean it out with carb clearner or petrol etc...because if you do when you connect it back up again any vapour or liquid left behind will get sucked straight into the turbo and your rev counter needle will then go to a place is never been to before if you start her up !

[missfixit70]

Wash it out & dry it thoroughly ( I used a hairdryer blowing through then left it to drain in the sun while I was doing other things) with a detergent after using any solvent type cleaner. all the pipework & inlet manifold will probably needa good clean too. Personally I'd blank off/remove the egr at the same time, as that is probably aiding & abetting the build up even if it isn't the primary cause.

[dave_aber]

How does oil / gunk etc get into the intercooler other than via worn turbo oil seals?