Stalling Bongo- "fly-by-wire" pump needs reconditioning?

[Guy83]

Bought a Bongo (1999 2.5l diesel) recently and it's spent all it's life so far with us in a a series of garages... sorting the overheating (leaking coolant pipe/airlocks), fuel tank reader (grounding), oil loss (rocker cover gasket), new tyres, half a dozen MOT advisories... The main problem remains that when up to temperature the engine gets rough, searches up and down with the revs and stalls. Gauze removed form banjo. A hand-held fuel tank held above the injector pump and feeding directly cures the problem, when lowered it starts again so suspect lift pump of injector pump.

Firstly- could it be anything else?
Secondly- where's a good place to get these more complicated injector pumps reconditioned? I talked to Bell Hill garage who gave me "Diesel Bob"- they said they could do it for 500-650 +VAT.

Thanks for any help on this!

[Bob]

Can't recommend anywhere, I'm afraid, but welcome to the Forum.

[Northern Bongolow]

Is it the pump, or something else, sounds like fuel tank vac, or the pick up pipe filter in the tank blocking, or the tank breather on the chassis blocked, the pipe goes from the top of the tank at the sender unit to the inside chassis leg just behind where the fuel tank ends at the rear, it's a black plastic round bobbin shaped filter the clicks into the chassis leg, pull it off the chassis, remove from pipe and rinse out and replace, they usually get covered in underseal or similar. Just inside the pipe where the filter fits is a one way valve, you can feel the hard piece inside the pipe, remove this and rinse also, making sure you return it the correct way round, this is to let the tank suck air in as fuel is used but not let fumes out.
Give it a check it may save you a quid or two.

[Guy83]

Thomas Fuel Injection in Blyth took the pump off but only replaced the front seal as this was clearly the main cause of the problem. There was still air being sucked in after the tank so the fuel lines were replaced too. Got a small leak on a glow plug: but it's too risky it might snap off if we try to remove...Be nice to get it out of the string of garages and back on the road hopefully tomorrow!