All smoke and no go....FIXED!!

[mikeonb4c]

With well over 100 BAR pressure produced by a diesel pump (modern TDIs produce 1600 BAR ) there's little chance of any foreign body lasting in there - unless it's lodged in the tiny filter.

Thought you might say that . So it has to be on the low pressure side then, whatever it is? Assuming it is this at all of course.

[owelly]

Righty-ho!
Engine back together and inlet pipes reconnected. Drivers seat somewhere close to where it should be.....
The vehicle starts fine and ticks over fine. It now pulls away a lot better and accelerates better. I'm not sure it's as good as it used to be because it's been getting worse over the past few months.
But it still smokes a lot on acceleration. Too much to be normal!!

I've definitely fixed something as it wouldn't even move itself away from the kerb before I started!

There is a bit of oil in the inlet/intercooler pipes so I'm wondering if the turbo is on it's way out. The spindle feels OK with no play but the seals could have wandered off.

I've had to resort to fitting a towbar to my Jeep to tow my Kit Car to a show this weekend and with no Freda, it means a retro-step to a flippin tent!!

I'll have another play next week.
Cheers for all the help folks.

[bigdaddycain]

Here goes a long (very) shot... Different car, so maybe not applicable...

Diesel engined fiesta would not rev past 2500rpm, checked/replaced all the usual suspects... After months of hair tearing frustration, it turned out to be an intermittent earth to the fuel shut off solenoid,triggered by a weird vibration when approaching 2500rpm...

The cable was loose in the spade terminal end,when earth was breached,solenoid kicked in, engine stopped A two second extra crimp cured it

[bigdaddycain]

Glad you have a part success there owelly,Scratch my last suggestion then!

[mikeonb4c]

Put it on 'special measures' with a heavy dose of injector cleaner and see if any further improvement? Afraid that's the limit of my technical ingenuity

[astrobyker]

Been watching this one with interest so I'd better share my thoughts. Engine runs with no reported bad noises so I assume nothing is seriously wrong mechanically inside the engine. The fact that there is plenty of smoke when the accelerator peddal is pressed suggests the fuel pump is working something close to how it should ie supplying more fuel the harder you push the peddal. As the increased fuelling does not result in correctly increasing revs or generation of much power there cannot be sufficient air being drawn into the engine to burn the fuel - hence the smoke. You say you have disconnected the intake on the engine side of the turbo, so there should not be any possible blockage in the air inlet ( I did originally think turbo broken). That really only leaves a severe restriction in the exhaust side of the engine preventing the revs rising to draw in air. I'm not familiar with the EGR system on the Bongo but I did see very similar symptoms on a Renault Scenic due to a EGR valve fault, complete loss of power and heavy smoke, similarly this fault developed quite quickly. Don't give up, there must be a reason for it, besides, I'd like to know the answer myself! One last thought but unlikely as I'm sure you would have noticed if something was causing compression loss. Probably be alot of noise from leaking head gasket or coolant being blown out of filler bottle.

[owelly]

Turbo.
It has to be the turbo that has poo'd its pants. I took the Freda for a scoot up the road and it went fine, apart from a bit too much smoke! But on the return trip, as the gearbox changed down and the turbo spooled-up, it lost power and poured out enough smoke to fill Uganda. The turbo whistle all but dissappeared.
The impellor on the turbo feels decidedly lumpy.......

Anyone known what other models have the same turbo? Or better still, a bigger turbo!!!

[scanner]

Turbo.
It has to be the turbo that has poo'd its pants. I took the Freda for a scoot up the road and it went fine, apart from a bit too much smoke! But on the return trip, as the gearbox changed down and the turbo spooled-up, it lost power and poured out enough smoke to fill Uganda. The turbo whistle all but dissappeared.
The impellor on the turbo feels decidedly lumpy.......

Anyone known what other models have the same turbo? Or better still, a bigger turbo!!!

Check what make/model it is - it should be marked somewhere and do a Google search or check around for one off an early Ford Ranger/Mazda B2500 pick-up.

[owelly]

The early Mazda B2500 wern't turbo'd. I've had my head under the bonnet of a Ranger and the cartridge (middle bit) look the same but with different convolutes fitted. I may be able to build one out of two....

[Doone]

Not sure what you've checked and not checked, we've pm'd you a couple of possibilities.

[owelly]

Cheers for the suggestions folks. It will be a few days before I get time to have another look. Watch this space.....

[astrobyker]

There's one e-bay at the moment:

http://cgi.ebay.co.uk/MAZDA-BONGO-FORD- ... dZViewItem

Jes.

[bigdaddycain]

Isn't the bongo turbo an IHI unit?

[owelly]

Forgive me Bongoliers, for I have sinned.........well, I parked the Freda up and forgot about it but with renewed enthusiasm, I bought another turbo and fitted it. It took about an hour by the time I had wrestled all the seized nuts and bolts into submission but it all went together fine.
The Freda started first turn of the key and drove fine. I went for a scoot around the village and it was pulling like a demented dentist. But then it lost power, started smoking like a furry-lipped teenager and started making a knocky, rattly noise. I limped home and drank coffee. That seemed to do the trick as when I went back to the Freda an hour later, it worked fine as I went to the shop for some milk. But then on the way back it did the same. Lots of knocking and smoke and not enough power to pull a mouse out of a traffic cone.
The turbo I took off is definitely pooped as the impellor has been munching the housing so fitting a new turbo has certainly fixed something but I still have a problem!! I'm looking for another Freda because I havn't the time to spend on this one so keep an eye out on Ebay for my bus as spares or repairs!!

[mikeonb4c]

Bummer. Especially as the solution is probably tantalisingly close. I'm not skilled enough to suggest anything that hasn't already been suggested a hundred times by others. I can only wish you good luck - a lucky break is what you need.