Bongo Fury

Hi Bongonauts

• '95 Diesel
• New head about 2 months ago (not my work).
• Trouble starting.
• Clouds of diesel smoke when spinning over
• More smoke when starting that clears very quickly
• Slight smell of fuel in cab
• Smells like it's running a bit rich
• Runs fine once going

Changed the glow plugs, but no joy. Noticed there appeared to be a pipe missing from back of one of the doo-dahs (techy, huh?) that is connected to the fuel pump/throttle. Should there be a pipe on here and, if so, where does it go to? And, could this be the cause of my starting problem?

Picture of part in question here: http://imigin.net/bongo/

All help gratefully received

Thanks
Ian

http://www.igmaynard.co.uk/bongo/forum/ ... n+actuator


Is it 2 at rear as simon jones says here as may be its blanked so no longer needed

yes it should have a pipe connected to it. if you look from the drivers side, to the rear of the pump, there is a steel pipe that is vertical heading up to the area that your solenoids are located.then it goes to a short flexy rubber piece then to the T piece shown.

look on this diagram its number 93-5104.

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

more worrying is the buz bar to the glow plugs touching the link pipe between the injectors, if it is (it looks like its close) you could have a potential fire. the buz bar has a plastic coating on it to protect from short circuits, it usually take a couple of weeks to rub through then it starts welding itself to the metal fuel pipes.

just had another look at the pic it looks like someone has fitted the wrong pipe. the black concertina pipe in the lower part of the pic is not proper vac pipe so maybe someone used this and its fallen off. . the pipe into the top of the solenoid is also loose, the one that is cable tied to the other. all these pipes must be proper vac pipe and be hot temp resistant or they will suck flat when hot.

Thanks

The buzz bar thing is an optical illusion - there is about 20mm between the bar and fuel injector pipe.

Had a look at the back of the fuel pump for another pipe, but all I can see are the two that go up to the solenoid together. Can't make head nor tail of the diagram, but thanks anyway. Need to have another look.

The black 'concertina pipe' is not a pipe, it is a protective covering on the fuel injector pipe.

I'll get my missus to have another look for a pipe at the fuel pump end, as she's always telling me that I've had a 'Man Look' when I can't find something!

I'll check the solenoids to make sure all pipes are secure as there appears to be a little puddle of fuel on the head just below them.

Cheers

Northern Bongolow wrote:yes it should have a pipe connected to it. if you look from the drivers side, to the rear of the pump, there is a steel pipe that is vertical heading up to the area that your solenoids are located.then it goes to a short flexy rubber piece then to the T piece shown.

look on this diagram its number 93-5104.

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

more worrying is the buz bar to the glow plugs touching the link pipe between the injectors, if it is (it looks like its close) you could have a potential fire. the buz bar has a plastic coating on it to protect from short circuits, it usually take a couple of weeks to rub through then it starts welding itself to the metal fuel pipes.

just had another look at the pic it looks like someone has fitted the wrong pipe. the black concertina pipe in the lower part of the pic is not proper vac pipe so maybe someone used this and its fallen off. . the pipe into the top of the solenoid is also loose, the one that is cable tied to the other. all these pipes must be proper vac pipe and be hot temp resistant or they will suck flat when hot.

Northern Bongolow wrote:yes it should have a pipe connected to it. if you look from the drivers side, to the rear of the pump, there is a steel pipe that is vertical heading up to the area that your solenoids are located.then it goes to a short flexy rubber piece then to the T piece shown.

look on this diagram its number 93-5104.

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

Just sussed the diagram out! That's the power of Shiraz! I'll have another look for the pipe in the daylight.
Ta
Ian

The fog thickens!

I have now found the correct pipe to attach the T from the solenoids and connected a vacuum pipe. Still won't start. However, the pipe that I found was connected went to a third pipe on number 3 (from left) injector banjo. So now I have a pipe coming from there and no idea where it should go. Any ideas?

Picture here: http://imigin.net/bongo/

Strange thing is, it was running okay (apart from a slight smell of diesel in the cab) when it came back from having the head done. Obviously, the numpty who did the job piped it up wrong, but why did it work for 4 weeks?

Can you please help? I'm getting desperate and don't want to scrap my Bongo after having just spent a small fortune on a new head.

Thanks
Ian

Manxda wrote:The fog thickens!

I have now found the correct pipe to attach the T from the solenoids and connected a vacuum pipe. Still won't start. However, the pipe that I found was connected went to a third pipe on number 3 (from left) injector banjo. So now I have a pipe coming from there and no idea where it should go. Any ideas?

Picture here: http://imigin.net/bongo/

Strange thing is, it was running okay (apart from a slight smell of diesel in the cab) when it came back from having the head done. Obviously, the numpty who did the job piped it up wrong, but why did it work for 4 weeks?

Can you please help? I'm getting desperate and don't want to scrap my Bongo after having just spent a small fortune on a new head.

Thanks
Ian

You really could do with talking to a Bongo professional. Adrian at JapanDirect in Bury 0161-763-3003 (who does mine) might be able to help if you call him. He does mine (including putting a new head on earlier this year) and may be able to give pointers. Tell him what Northern Bongolow has said, as that might help him work out what's happening. Might be best if you ask if your mechanic can call him. Don't panic though, it'll hopefully be something very fixable. Good luck and keep us posted.

Thanks NB

I used to live near Bury. No Bongo specialists here on the rock, though. Anyway, I'll give Adrian a call.

Thanks for your help.
Ian

mikeonb4c wrote:

Manxda wrote:The fog thickens!

I have now found the correct pipe to attach the T from the solenoids and connected a vacuum pipe. Still won't start. However, the pipe that I found was connected went to a third pipe on number 3 (from left) injector banjo. So now I have a pipe coming from there and no idea where it should go. Any ideas?

Picture here: http://imigin.net/bongo/

Strange thing is, it was running okay (apart from a slight smell of diesel in the cab) when it came back from having the head done. Obviously, the numpty who did the job piped it up wrong, but why did it work for 4 weeks?

Can you please help? I'm getting desperate and don't want to scrap my Bongo after having just spent a small fortune on a new head.

Thanks
Ian

You really could do with talking to a Bongo professional. Adrian at JapanDirect in Bury 0161-763-3003 (who does mine) might be able to help if you call him. He does mine (including putting a new head on earlier this year) and may be able to give pointers. Tell him what Northern Bongolow has said, as that might help him work out what's happening. Might be best if you ask if your mechanic can call him. Don't panic though, it'll hopefully be something very fixable. Good luck and keep us posted.

the link pipes from the injectors need to be connected up from each injector then return to the pump.

if you look at this diagram on the fuel system this shows how this wrong pipe fit has occurred as both the fuel pipe return and the vac supply come up the back of the pump and end at about the same place. the smell of diesel is due to this return pipe being incomplete.


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

It looks like you need to refit/replace the hose pipe between the leak of pipe assy and the pump,it is quite an awkward but doable job owing to the pipe run behind the manifold,if needed this is the pipe you will require.

http://www.ebay.co.uk/itm/GENUINE-MAZDA ... 417f55522d