Mazda Bongo 2.5 TD pump seal

[Jimbob738]

If there is a gee diesels near you would be a good place to start or any diesel service centre and i think looking around the 400 pounds mark i recon.

they aint cheap nor easy to mess with im lucky it was a seal leaking.

Jamie

[helen&tony]

Hi
Thanks, but a bit far! ...I'm looking more to buy/ ship!
Cheers
Helen

[progroup]

Hi
Thanks, but a bit far! ...I'm looking more to buy/ ship!
Cheers
Helen

Me too helen!
These are precision built devices requiring bench calibration. It is phyically impossible to calibrate mouonted on the vehicle as I failed to realize in my situation. I was warned! I couldn't justify another $1,200 CDN investment into this particular Bongo. My Bongo has NO fair market value or ZERO dollars! In my case, I like most aspects and utility of the Bongo, but at $5k initial investment plus over $3k more in parts & taxes/duties/shipping, I'd determine that I must do this myself regardless of the risk. In my over forty years as a mechanic, I have never rebuilt a pump like this. Mechanically, I had no issues and a complete success! However, due to the overall condition of my Bongo 197,000kms, other problems/issues surfaced which spoiled my efforts.

I would seriouly consider a good used from a trusted breaker/wrecker for $200 GPD 'ish; have it shipped to you, and change three seals prone to leakage as a preventitive measure BEFORE swapping in. The 'distribrution head large O-ring' ; 'Input shaft seal', and the TWO 'green' O-rings' on the 'Advance Timing Piston'.

There is a specific method to change these seals on the bench without disturbing the integrity of the pump's calibration.

I am a gini-pig when it comes to Bongo challanges because the vehicle is more of a hobby of mine. I own other late model NA cars. The Bongo is unique because it is 4WD, Diesel 2500cc, Auto, 8 pass, AFT, and can tow my ATV's and camping gear OR Trailer RV.

If I continue w/BongoBonnie; I am looking to import some additional usede parts [like another pump at least]. From a Canadian's perspective, my Bongo is like a 6 to 7 year old vehicle even though it is actually 17 years old.

All the best,
Dave

[Jimbob738]

Interesting take i gather the pump is one of the most complicated things on the van whats other peoples take on them?

im now thinking of getting another to recon and fit, one with less miles my van on 145 km.

Jamie

[progroup]

Interesting take i gather the pump is one of the most complicated things on the van whats other peoples take on them?

im now thinking of getting another to recon and fit, one with less miles my van on 145 km.

Jamie

Yes, I would recommend that if budget permits. You have over 15,000 Bongos/Fredas in the UK. I am certain that there is an abundance of good used reliable parts for the taking. I was quoted about $200GPD from BongoBits just before they went BongoBUST a few weeks ago. try Vaughn at AVA Leisure. I had a good talk with with resently about Bongo parts in general. His contact info is on this site.

The FIP is the 'heart' of the Diesel Bongo. Be real careful if you choose to re & re yourself. I haven't uploaded my most recent videos and stills regarding this process as yet. you should review them on YouTube when I notify the link BEFORE attemping.

I have found that the leaking FIP is more than a couple of green seals. That may be just the beginning!

Cheers,
Dave

P.S. You MUST have access to TWO main tools namely a Bosch VE Pump dial Indicator Kit for bongos [made by AST Tools I think - check ebay.co.uk for the source at $110GPD for the kit] plus a good small steering wheel puller set with 45mm x M6 cap head bolts to extract the internal timing gear from the input shaft of the pump. carefull to orient the woodriff key 12 o'clock high so as not to drop inside the timing gear case. Wrap some elecrical tape around the exposed shaft over the woodriff key until servicing on the bench.

[Jimbob738]

You know what your read my mind i did kind of think this maybe just the sign that more issues are around the corner with the pump i might see what i can afford tonight.

Regards

[Jimbob738]

I have fixed my lights the flasher box was full of water dried out cleaned connections what do ya know all working now.

i fitted the new seal on my pump (the easy side) yestarday tightened it up plenty still expressing a little have i done something wrong its not pissin out just a drip on hard revs, i have the green bosch seals from this site they seem right?

is there a special way of doing it all parts went back in as they came out does it fit only one way up?

Advice please?

[dandywarhol]

Any Bosch diesel centre will be able to recon the pump - the Zexel pump on the Bong is built under licence from Bosch

[teenmal]

I have fixed my lights the flasher box was full of water dried out cleaned connections what do ya know all working now.

i fitted the new seal on my pump (the easy side) yestarday tightened it up plenty still expressing a little have i done something wrong its not pissin out just a drip on hard revs, i have the green bosch seals from this site they seem right?

is there a special way of doing it all parts went back in as they came out does it fit only one way up?

Advice please?

Hi,check the cap and make sure its not warped,give the face a good rub down on a flat emery surface,and make sure the groove is clean.Also check the seal for nicks.

Cheers.

[Jimbob738]

Thanks sounds more like a useful answer if the cap was worn what could be done ill do what you suggested

Jamie

[dandywarhol]

info here

http://www.igmaynard.co.uk/bongo/forum/ ... pump+seals

[Jimbob738]

info here

http://www.igmaynard.co.uk/bongo/forum/ ... pump+seals

Life saver why didnt you point me to this sooner dude many thanks.

[The Great Pretender]

Any Bosch diesel centre will be able to recon the pump - the Zexel pump on the Bong is built under licence from Bosch

Made me wonder too, it's a bog standard IP, why all the reticence from companies?
Is it's because it has been "played with"?
Also wonder why there was no response to the other post where I queried the governor build.
http://www.igmaynard.co.uk/bongo/forum/ ... 4&start=15
Ain't rocket science is it..................

[helen&tony]

Hi
Progroup ( Dave )
You have the same problems with parts...although some English over here say OEM parts for Japanese cars are way cheaper than the UK, it usually turns out as Moo-Poo , as "ex-pats" usually like to demonstrate how knowledgeable they are , and they are second only to the indigenous population, who are apparently highly qualified (more moo-poo), and like nearly all qualifications here, they are either bought or forged , however, I have found a group of young spannermen who seem highly enthusiastic, and motivated, and can handle a job in "book time" or less (always a good sign), and i've watched them work...capable but not skilled.....so...I choose not to trust them on a pump rebuild. I can strip and repair it, but set it up....no! I have the added advantages of age and injury / ailments, that a simple task like last years waterpump change took me 3 days, as I can't stand for long, or perform such tasks without a break every few minutes
SO....to the point...If you find any person willing to ship a good pump, let me know, as I'm gradually replacing most ancilliaries, or getting them repaired...same as you, mine is 17 years old, and too darn' useful
Anyway, if you get fed up with diesel, I have found a Canadian firm doing a nice electric motor conversion for Ford Ranger motors, if I can find the addy
Cheers
Helen

[progroup]

Hi
Progroup ( Dave )
You have the same problems with parts...although some English over here say OEM parts for Japanese cars are way cheaper than the UK, it usually turns out as Moo-Poo , as "ex-pats" usually like to demonstrate how knowledgeable they are , and they are second only to the indigenous population, who are apparently highly qualified (more moo-poo), and like nearly all qualifications here, they are either bought or forged , however, I have found a group of young spannermen who seem highly enthusiastic, and motivated, and can handle a job in "book time" or less (always a good sign), and i've watched them work...capable but not skilled.....so...I choose not to trust them on a pump rebuild. I can strip and repair it, but set it up....no! I have the added advantages of age and injury / ailments, that a simple task like last years waterpump change took me 3 days, as I can't stand for long, or perform such tasks without a break every few minutes
SO....to the point...If you find any person willing to ship a good pump, let me know, as I'm gradually replacing most ancilliaries, or getting them repaired...same as you, mine is 17 years old, and too darn' useful
Anyway, if you get fed up with diesel, I have found a Canadian firm doing a nice electric motor conversion for Ford Ranger motors, if I can find the addy
Cheers
Helen

Hi Helen... Thanks you for the comments above; but to clarify, are you DYI 'ing the Bongo yourself? What's Tony doing?
My wife is looking forward to learning even less about the Bongo. We share a lot of desparate laughs over the thing!

Anyway, there are no parts here in Canada. If I get hit in the most minor fender bender, our Insurance Corp will riight-off the vehicle in a hurry. Even a damaged front windscreen spells disaster. I would have to import any/all parts from the UK.

The problem for me is threefold now... I'm in too deep, can't say no, and don't know when to cut my losses...