After a late night call from Northern Bongolow, and a patient couple of hours this evening, i'm happy to report Dobby's coolant now seems completely air-free, with no damage seemingly done.

During this third attempt at a bleed, almost all the air was removed before the engine was even turned over ...

I'm pretty sure we're following the process as you described ... cold see-saw, then tick-over see-saw, then 2.5k revs for 3 mins, and 1 min idle

Really kind of you to offer help - THANK YOU - will PM you now

Thanks for the reply teenmal :)

Think I'll order a replacement thermostat and radiator- can't find a receipt in the history for a replacement for either - and there was some sludge in the old coolant so may be blocked.

So is it usual to see a continuous , uninterrupted 60 second eruption (coolant ...

Just replaced several of the coolant pipes on the V6, after finding dripping from junction of top rubber hose to driver's side metal pipe. She has smelled 'hot' after a few 30+ minute runs recently (maybe the leaking coolant evaporating?), and metal pipe end looked quite rusty.

To bleed, we're ...

It's taken quite a while but I'm over the moon to confirm she's back on the road! HOORAY!!

The main delay was replacing the oil pump, which had to come from Japan - they don't seem to be a common fault on our wagons so no-one holds new stock. When it arrived a couple of weeks later it didn't ...

Not attempting this myself as van is still with RD Motors.

Just trying to get my head around what's involved and listen out for the experiences of others. It seems that oil pumps don't come out very often so any stories of the good/bad/ugly all appreciated.

Thanks again for the generous advice. An ...

Thanks Rita and Bongolia.

A pic showing the damage to crank shaft end a bit more clearly (clockwise from 12 o'clock):

https://samwestlake.co.uk/wp-content/uploads/2017/05/crank-shaft-view-2-e1494672598924.jpeg

If we go down the route of replacing the oil pump (or just the case part?), any ideas ...

mikeonb4c - Very happy to share. I've learnt a lot from other's sharing here ... warts and all.

Bongolia - You're a firestarter, twisted firestarter ... and I'm furious! Details and a pic of the damage here ... http://igmaynard.co.uk/bongo/forum/view ... =3&t=73623

Hello all ... I wondered if anyone has tackled this problem before?

While investigating odd knocking noises from the engine (turned out to be a noisy tensioner pulley), local mechanic Graham from RD Motors removed the old crank shaft oil seal and found marks on the shaft where it spins inside the ...

The Bongo's finally been up on the ramps, timing belt covers removed, and the noise tracked down to the tensioner pulley. Should be fixed with a replacement (or maybe only new bearings). This clears up the mystery of the where the knocking was coming from, and no harm done :D

5 new seals on order ...

No oil pressure test yet , Rita. Roy squeezed me in on a busy Friday afternoon and seemed confident that problem was unrelated to oil pressure.

It will be the first thing done when she goes back in to the garage though.

Note to self: avoid scary engine noises near to spring Bank Holidays, and if ...

Cheers again for your thoughts on this Bongolia. You're right: cam belt tensioner it is, and not driving is a VERY good idea!

I'll sit tight for a week ... goes in to the garage 8th May. Shame to miss the Bank Holiday camping trip, but with luck, we'll ride again

So Roy at R D Motors (lovely bloke, and seems knowledgeable about our favourite four wheels), got the Bongo up on the ramps and had a good listen earlier.

Although he's never heard that particular knocking noise before (he brought another Bongo mechanic over for a listen too, who was none the wiser ...

I gave Roy at R D Motors a call this morning and we spoke for a while.

He reckons that the best place to start is to have a listen to the noise. That and an oil pressure test. So i'll be taking the van to him Friday lunchtime.

Keeping everything crossed now ...

Thanks!