vacuum hose assembly

[anucatone]

Hi All,

I thought I'd save myself some money and change the glow plugs on my 2.5TD myself. Unfortunately, while moving the vacuum hose assembly to one side in order to access plugs 3 and 4 I managed to break two of the plastic spigots that the vacuum hoses squeeze on to. This was because the hoses had hardened with age and so wouldn't flex enough to allow the leeway required,

The first spigot is on the big air inlet pipe down below, and connects via a hose to a green and white ball-shaped one way valve. The other one is attached to one of the four electrical plugs on the assembly and connects via one of the hoses to a round metal thing to the left which looks like a bit like a distributor.

I don't see any way of repairing them because they've sheered off right at the base and they're so small they don't have enough surface area for them to be glued back on.

Does anyone know what they actually do? The van's running fine with them both disconnected at the moment. Sorting it out looks like a case of replacing the entire vacuum hose assembly, electrical plugs included, and a big section of the wide bore hose out of the air filter.

I'm inclined to ignore it but worried I may be storing up trouble.

[dobby]

Don't know what they do but someone will. I repaired the smaller one with a biro refill inside the broken 'tube' section and reamed the lower bit to accept it and use (I think) araldite to fix it.

Worth a search but this thread might help


http://igmaynard.co.uk/bongo/forum/view ... 91#p286191

[mikeonb4c]

Don't know what they do but someone will. I repaired the smaller one with a biro refill inside the broken 'tube' section and reamed the lower bit to accept it and use (I think) araldite to fix it.

Worth a search but this thread might help


http://igmaynard.co.uk/bongo/forum/view ... 91#p286191

Interesting. I'd have thought the polythene type material of a biro refill wouldn't have gripped with the glue, but either it has or else it's acting as a joining piece regardless. I often use a piece of roughed piano wire or panel pin in these situations, plus maybe a strip of nylon bandage impregnated with araldite and wound tight. That's wot I dun with my dipstick.

[Northern Bongolow]

for the large dia pipe repair get a high pressure inner tube from a racing bike unscrew the entire valve assembly, then drill out the large pipe and screw the valve into it, then trim/hacksaw the top off to the required length then refit your pipe.

the other pipe sounds like it goes to or from the erg valve, look on this link.

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

or this for the large pipe.

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

this link shows the egr valve which is mounted at the back drivers side of the head,

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

[anucatone]

Thanks guys,

I've ordred a couple of 3mm threaded nipples http://www.ebay.co.uk/itm/390948209350? ... EBIDX%3AIT which if I drill the hole out on the big diameter pipe I should be able to screw in to the base of the broken nipple.

However the solenoid nipple, which is at the other end of the pipe from the EGR valve, is snapped off right at the base and I'm not sure about drilling into that because I'm not sure what's on the other side -- i.e. there might not be enough depth available to thread a replacement nipple into it. Am I right in saying the biro technique is predicated on there being a stump of the nipple left in which to accommodate the biro refill tube? On mine there's nothing but a tiny whole, about twice the width of a paper clip wire. The nipple itself is snapped off in its entirety.

[dobby]

Thanks guys,

I've ordred a couple of 3mm threaded nipples http://www.ebay.co.uk/itm/390948209350? ... EBIDX%3AIT which if I drill the hole out on the big diameter pipe I should be able to screw in to the base of the broken nipple.

However the solenoid nipple, which is at the other end of the pipe from the EGR valve, is snapped off right at the base and I'm not sure about drilling into that because I'm not sure what's on the other side -- i.e. there might not be enough depth available to thread a replacement nipple into it. Am I right in saying the biro technique is predicated on there being a stump of the nipple left in which to accommodate the biro refill tube? On mine there's nothing but a tiny whole, about twice the width of a paper clip wire. The nipple itself is snapped off in its entirety.

I'm hoping Ive got it right but yes you enlarge the small hole to receive the biro refill and it fits into the broken bit. The glue bonds the two parts not the refill tube. Sorry no pictures, did it years ago

[Northern Bongolow]

i did very similar to the above by dobby, i used roll pins.

https://www.google.co.uk/search?q=roll+ ... B400%3B400.

i got a tiny one into the hole then fitted a larger dia one rotated at 180 deg onto that 1st one, this gets you up to the internal dia of the tube to be fitted to it. spread a bit of glue about then its good and strong.

the inside of the valves is just a spring and flat steel disc,this blocks the ports. put a bit of lube in there once fixed as the condensation inside them can rust the internals.