Head Gasket / Cracked Head.

[matthenley]

So, a week after having my motorbike stolen, Bongo overheats big time, causing a pipe to rip. After replacing the hose, I refill the coolant and while bleeding, coolant is ejected from the bleed pipe at force, followed by exhaust gasses. Experience (I used to own an MG) tells me head gasket or cracked head.

Can't really afford the repair at the moment (after buying a new bike), although I need the bongo for when it's too icy to commute on the bike. My considered options:

Bottle of gunk
Get a bottle of steel seal, which could get me through the winter, when I could get it repaired, if needed. From here, amazon reviews, etc., it seems about 50:50 for success and could have to clear the gunk later (although the gunking seems to be more from using OAT/long life/Halfords red coolant?)

Attempt a head gasket replacement myself
Looking at the youtube videos, it looks like I *could* be able to do this. I have a mechanic neighbour who could help out when/if I get completely stuck (which would hopefully be less time/expense than doing the whole thing). There's a place local (Doncaster) that can pressure test and skim the head.

I'm thinking at the moment, Steel Seal is worth a try. If everything goes completely wrong, attempt a repair. There's people on eBay replacing engines for like £1k if everything fails. Any experience of these?

So I'm wondering:
Am I making a mistake trying Steel Seal?
Am I making a mistake trying the repair myself if/when Steel Seal doesn't work?

Matt

[mikeonb4c]

I'd have to advise against steelseal as I can't persuade myself that any temporary upside won't leave a permanent downside. I wonder also what night have caused your problem. Was the coolant rusty coloured? I reckon I'd go for the DIY repair option. Plenty of support on here from those who've done it successfully. You may need to factor in cost of radiator replacement etc if that's what caused the problem.

[matthenley]

Thanks mikeonb4c,

Yeah, rusty coloured coolant. Had the Bongo for about 6 months and I think it's been gradually there since then. Coolant has had to be topped up every so often and there's rusty water marks under the header tank.

Matt

[mikeonb4c]

Thanks mikeonb4c,

Yeah, rusty coloured coolant. Had the Bongo for about 6 months and I think it's been gradually there since then. Coolant has had to be topped up every so often and there's rusty water marks under the header tank.

Matt

Coolant system overhaul needed I fear. Sorry to be bearer of bad news. But an otherwise good condition Bongo is hard to throw away. It would make a really satisfying DIY project which, done over time takes the pressure off costs etc (every month not driven is 150 quid saving for me!). And Simon Jones, Maxheadroom, and Driver+Passengers can all confirm good outcomes esp. when the job is done with care and diligence. Good luck.

[helen&tony]

Hi
Ah...you may have a crack in the header tank if there's a water-mark under the tank!...Haydn found one or two tanks with splits!...I recently put a new one on mine...not damaged, but as it's old, I thought I'd replace it!....It might be worth unbolting it and taking a peek with the hoses still connected!...It might be the cause of your over-heating if there's a pressure loss.......but I second what Mike said about the Steel Seal...definitely have a go yourself if you're confident, and go for a new head. Check the "Sticky" at the top of this section re: buying a new head!
Cheers
Helen

[mikeonb4c]

Hi
Ah...you may have a crack in the header tank if there's a water-mark under the tank!...Haydn found one or two tanks with splits!...I recently put a new one on mine...not damaged, but as it's old, I thought I'd replace it!....It might be worth unbolting it and taking a peek with the hoses still connected!...It might be the cause of your over-heating if there's a pressure loss.......but I second what Mike said about the Steel Seal...definitely have a go yourself if you're confident, and go for a new head. Check the "Sticky" at the top of this section re: buying a new head!
Cheers
Helen

Quite right Helen. I was so busy thinking about rusty coolant I didn't address the cause of coolant loss. Worth checking header tank just in case.

[helen&tony]

Hi
The one thing we all forget is that the Bongo cooling system was designed by someone with shares in a rubber hose factory, and more closely resembles an offering of knitted spaghetti, and if you find one fault, then you may have more...go through the whole lot with a fine tooth comb , and if you go for a new head, at least you know it won't suffer the same consequences if you have checked everywhere...AND get a pressure test to find potential sources of coolant loss when you have the new head fitted!
Cheers
Helen

[Titan1995]

Steal Seal was successful for a month or so on my Bongo.

Crack in the head eventually one the day though.

It might give you a bit of time until you can do the job yourself.

Follow the instructions to the letter on Steel Seal.

I eventually replaced the cylinder head and most of the major coolant items.

Head replacement not so bad a job. Having done mine. Might need a hand here and there and some good quality tools. Head bolts very very tight.

[Northern Bongolow]

may be an idea to go the full engine swap route.
by the time the head has been checked,skimmed, replaced,new gasket/bolts, the bill could be £500-£700. plus time.

try george near halifax-------bongospares2012 on ebay or the internet.

as helen says, get the whole system pressure tested first before you pull it all down to establish the cause.

[Velocette]

may be an idea to go the full engine swap route.
by the time the head has been checked,skimmed, replaced,new gasket/bolts, the bill could be £500-£700. plus time.

try george near halifax-------bongospares2012 on ebay or the internet.

as helen says, get the whole system pressure tested first before you pull it all down to establish the cause.

It is a bigger gamble IMO if you intend to keep the car. I would prefer to have an engine I had repaired properly to one I know nothing about. If you are going to sell it and cut your losses engine swap every time.

[David Edwards]

I spent nearly 18 months trying to get my engine fixed and bought loads of new stuff for it, didnt work, in the end I took a gamble and bought an engine from george at bongospares2012 awesome service,engine is perfect and was 99% complete to be fair, only used my air con compressor I think,lol. Nice down to earth chap too.

[matthenley]

Thanks for the replies all. And Happy New Year!

Okay. I'm going to go for it. I'm actually quite looking forward to the challenge. I like the idea of knowing the engine and learning from this.

I'm going to use YouTube user BongoBonnie's videos to help. The videos are here: http://www.youtube.com/user/BongoBonnie

I'll keep this thread updated and try and add some pictures - it may help others tackle it later and will help me organise my thoughts.

Todays Work

1. Remove the centre console, passenger front seat and all of the metal housing underneath the centre console. Have a look for anything else that might need replacing.

2. Order the parts:

Get a new head. Reading other comments, I don't want to either do all the work and then have to replace the head later and I don't want to pay £80 for pressure testing and skimming to find I need to get a new head anyway. Not going to trust eBay suppliers for this and this seems a resonable (if expensive ) price for this. Comes with head gasket and bolts.
http://www.bongobits.com/index.php?main ... cts_id=143

Replace the temperature switch (which turns the fans on). Not sure if it works or not but while I'm down there, I might as well for the price.
http://www.bongobits.com/index.php?main ... cts_id=176

*Anything else I should change while I've got the engine apart? Cam belt was changed before I bought it last year*

I'll need a torque wrench:
http://www.screwfix.com/p/reversible-to ... 1812139186
The torque settings are here:
http://www.justanswer.com/uk-car/3k6j0- ... uence.html (mentioned now so I can find later!)
I'll need a 12 point impact socket. I've bought a set.

3. Start checking the cooling system for the cause.

Thanks everyone for your help.

[Simon Jones]

Well done for taking it on. Lots of people have successfully changed the head and it's well worth doing it yourself. A few things to add to your shopping list:

- New cambelt (and possibly tensioner). You should not re-use the existing one as it will be weakened by removing and refitting it.
- Head bolts (looks to be included with the head you are looking at)
- Water pump
- Thermostat
- Head gasket set (looks to be included with the head you are looking at)
- Oil and filter
- 5 litres of anti freeze
- Oil feed tube between the block and head (available from Bellhill Garage)

Do lots of research on the forum for folk who have changed the head / gasket before. I changed the gasket on my previous Bongo several years ago and it is still going strong many thousands of miles later. My two top tips are to 'deck the block' and use Wellseal gasket compound. Have a read up on both subjects, with particular attention to the detailed thread from Matt (Driver+Passengers).

[mikeonb4c]

Bongobits seemed to go through a bit of a sticky patch - are they trading again ok?

Try and check that radiator flow is ok and if in doubt fit a new one. Alternatively I suppose an engine block temp gauge might be used as insurance. I'm just concerned that you identify what might have lead to the head failure, and so avoid a repeat. Good luck and well done. I think it will be a satisfying and rewarding challenge. And the longer you spend on it, the more you save (well sort of)

[the laird]

If its a diesel change glow plugs and would be worthwhile fitting a coolant alarm if it ain't got one,I think using good parts would be a safer job than the other which we all read and learn about best of Scottish luck to you.will watch your progress