Catastrophic cylinder head event - advice needed

[Signof4]

Hi all
I bought a Ford Friendee (4WD 2.5L Turbo-diesel P reg) privately about a couple of months ago. It had done 86k miles, and had a new MoT. To my untutored eye it looked to be in pretty good nick for its age. I had a coolant level alarm and cam belt set fitted and the vehicle was serviced. I also asked the mechanic (one I have used on several of my vehicles for years) to check the van over and do any necessary work. He reported that it seemed a good Bongo - he had seen a lot of bad ones - and apart from a bit of minor welding before its next MoT (sills and a cross member) it was in good health.
I pootled about in the van for about 600 miles and the other day I was driving back from the seaside at about 60 mph and without warning felt a big thump as though I had run over something. The engine immediately lost compression and I cruised to a halt. I got the van transported to the garage by the AA and by the time we got there the coolant alarm was going when we turned the ignition on. The engine sounded as though it was trying to fire. The coolant level was just above the lower pipe in the coolant tank.
I spoke to the mechanic the next day. He confirmed a damaged cylinder head and said he needed to strip the system down to assess for any further damage. He admitted to being mystified about the cause and was not sure what the thump could have been. The coolant alarm hadn't sounded at the time and he had checked the cooling system for leaks etc previously.
Needless to say, I'm hugely disappointed as I took every precaution I thought possible to avoid this situation. Have any of you got any ideas about what happened and a possible prognosis for the van? Was I sold a turkey or is this sort of thing common in Bongos?
Any advice would be much appreciated.

[Velocette]

If the head gasket failed it could have pressurised the header tank, raising the coolant level, the coolant alarm will then not sound until the pressure and temperature have dropped. This is what happened to me. I have since fitted a digital temperature guage/alarm in addition to the LCA.

It does not necessarily mean you have bought a dog, it is just bad luck IMO. Vehicles over 7 years old are prone to head gasket failures depending on how they have been used which is impossible to assess from mileage and condition.

If it is any consolation I had a new head, cam belt , water pump, thermostat and radiator fitted and have since done two long European Trips with no more bother.

[mikeonb4c]

Oh dear, sorry to hear your news. Bongos are good cars, with a lot of outstandingly reliable workhorses out there. But where trouble does occur with the 2.5TD, problems with head and head gasket lead the way (and it usually happens due to a failure in the cooling system).

I bought private and the budgetted £1.5k I saved over dealer price to one side in case of trouble which, as Velocette says, can always strike with an old car of uncertain history. Luckily I didn't need it, but if I had of, I'd have had to have been philosophical about it.

Turning back to your specific symptoms, they sound a little untypical for a head failure (although even so it does sound a bit like the head may have gone). How familiar is your mechanic with Bongos - what makes him absolutely certain that the head has to come off?

Had the car had a coolant alarm on it for a long time, or is it possible the vendor fitted one to make it attractive at the time of sale, or maybe after an incident that had been a close shave?

Oh and where are you based, in case there is a Bongo specialist near you?

If the head does have to be done, make sure a good quality replacement is fitted (kits from the Bongo Fury shop are said to be good and come with all bolts etc) and make sure the engine block is cleaned up and flatted to produce a really good mating surface. BF member Simon Jones described how to do a good DIY job, some while back, and I think he even used gasket sealant for good measure even though it is not strictly needed.

Keep us posted on this and good luck.

[dobby]

Its an awful experience but breathe in sharp get the head done as well as much as the cooling system as you can afford and look forward to many happy years use.

Ours went in 2009 after 4 years ownership (it had done about 80,000 miles) and whilst we are as cautious as ever and we treated as an ill afforded investment.

Hope you get it all sorted

[carlioll]

As this happened shortly after a cam belt change I would be looking in that area . Pistons and valves easily meet if the timing goes wrong due to incorrect fitting of timing belt

[Signof4]

Hi all
Thanks for your encouraging responses and advice. I was a bit downhearted when I started this thread.
I saved quite a bit on what I would have paid a dealer and planned to put the savings away for Bongo maintenance. It looks like I'll be using it sooner than expected. Mikeon4bc - I had the coolant alarm fitted when I bought the bongo and I live near Canterbury in Kent. I've used the same garage for some years and have faith in the mechanic who services our vehicles. I understand the engine is pretty standard, but I'm no expert on this.I think I'll take Velocette's advice and have a digital gauge fitted.

Once again, thanks for the encouragement and advice. I'll let you know how it goes.

[Velocette]

Hi all
Thanks for your encouraging responses and advice. I was a bit downhearted when I started this thread.
I saved quite a bit on what I would have paid a dealer and planned to put the savings away for Bongo maintenance. It looks like I'll be using it sooner than expected. Mikeon4bc - I had the coolant alarm fitted when I bought the bongo and I live near Canterbury in Kent. I've used the same garage for some years and have faith in the mechanic who services our vehicles. I understand the engine is pretty standard, but I'm no expert on this.I think I'll take Velocette's advice and have a digital gauge fitted.

Once again, thanks for the encouragement and advice. I'll let you know how it goes.

I fitted mine about an inch down the "Glory Hole" after reading that they are hard to read in bright sunlight. I actually ease off now if the temp goes above about 92 as I know I am working the engine hard unless I am climbing a mountain and it can't be helped. I couldn't recommend them highly enough, even Mrs V watches mine!

[David Edwards]

I have had mine for 9 years and no probs, get it serviced every six months and every week do my full checks on it, oil,water, lights etc,still didnt stop it dropping a valve on me with no warning whatsoever, repaired under R.A.C warranty.

[Wendy'n'Alan]

Sounds exactly what happened to us in Ireland - had to replace cylinder head with cam shaft as the cam shaft had shattered!! Got it back Tuesday

[Signof4]

Hi
I got the verdict from my garage yesterday. It's a dropped valve, not a coolant problem. The valve has broken the cylinder head and a piston needs replacing. Very expensive, but I'll have to get it done Could this be anything to do with the recent cam-belt change (Carliot?) or as per David Edwards, does this kind of thing happen with Bongos?

[Velocette]

Hi
I got the verdict from my garage yesterday. It's a dropped valve, not a coolant problem. The valve has broken the cylinder head and a piston needs replacing. Very expensive, but I'll have to get it done Could this be anything to do with the recent cam-belt change (Carliot?) or as per David Edwards, does this kind of thing happen with Bongos?

From what I have read on here, and I read this forum a lot, dropping a valve is pretty rare. One way it can be caused is by the valve failing to seal which could be due to a tight tappet. This causes the valve to heat up abnormally. Potentially worn or loose valve guides could also do this as their secondary function is to transfer heat to the head.

One thing to check is that you have the original head as there are some bad pattern heads around.

[David Edwards]

Well I bought a new head, pistons,arms, gaskets. seals and loads of other stuff, all as you know expensive, result, ordered a new engine yesterday and wish I had done it at the start, would have saved me a lot of stress and bother, to be fair the RAC warranty on the bongo will still pay me out £475.00 towards it tho, so hoping to get it back soon.