Dashboard Removal

[CheekyRich]

Hi guys

Can anyone help with some advice on how to remove the dashboard? I've disconnected all the electrics and undone the bolt in the front centre of the dash next to the windscreen. I've also removed the 3 screws in the driver's footwell on the bottom section of the plastic dash next to the windscreen. Having a look around, I can see more screws which secure the plastic dash to the metal tube bar section beneath the plastic dash. Some of these screws seem extremely difficult to access, perhaps impossible with the dash in place (such as those at the back of the instrument cluster housing which need to be screwed in from behind the housing. Do you have to remove the metal tube bar section underneath as well in order to remove the plastic dash?

Metal "tube" section can be seen here (the top part of the diagram.)
http://lushprojects.com/bongopartsmk2/c ... o=.html#24

I know this metal section underneath has 6 12mm bolts (2 at each end and 2 in the centre) securing it.

Having removed these 6 bolts, the whole dash assembly is looser but there are 2 more bolts securing it to the steering column. I'm reluctant to remove these because it's all looking a bit complicated and of I can't get it back together (I'm working alone) I'm screwed. It's also a rats' nest of wires. I've labelled them but rerouting them and getting them held in place at the correct places when putting it back together might be a nightmare.

I've looked at the diagram linked to above but it's not too clear exactly which fittings hold which part in place and whether the plastic dash can be removed without the metal bar section underneath. The reason I'm doing all this is to remove the ducting ("trunking") that directs the air to the vents to give it a thorough clean.

Ducting I'm trying to access:

http://lushprojects.com/bongopartsmk2/c ... no=.html#7

With most of the work seemingly done in removing the plastic dash and all electrics disconnected, I'd like to persevere and complete the job...

I tried uploading photos but seem to get the "filesize too large" message even with images that are less than 100KB.

Any advice would be great. Please help if you can!

Thanks,
Rich

[mikeonb4c]

Yikes sounds complicated. Do you have good reason to believe the ducts need and will benefit from a good clean? Mine seems fine after 21 years although cleaning the heater matrix and removing remains of filter gauze made a huge difference to removing smell caused by aged mildew as well as improving airflow.

[Bongolia]

You dont say why you are removing the dash but If its just a clean through you need then you can buy from most motor factors a sterilizing and deodorizer "bomb".
Run the engine and set your ventilation to recirc, fire the bomb and let it run with the doors shut. May need two if its really smelly. Never known them to fail to clear odours unless there coming from somewhere else of course.
I don`t know what model you have but on mine,2.0Ltr petrol, and after sterilising,I cut down a pollen filter and installed that in the air ducting as I suffer a bit with hay-fever works a treat.

[mikeonb4c]

You dont say why you are removing the dash but If its just a clean through you need then you can buy from most motor factors a sterilizing and deodorizer "bomb".
Run the engine and set your ventilation to recirc, fire the bomb and let it run with the doors shut. May need two if its really smelly. Never known them to fail to clear odours unless there coming from somewhere else of course.
I don`t know what model you have but on mine,2.0Ltr petrol, and after sterilising,I cut down a pollen filter and installed that in the air ducting as I suffer a bit with hay-fever works a treat.

The bomb approach only partially/temporarily cured my mildewed matrix problem (something imported Bongos seemed prone to) but the dismantle and clean did and i suspect the bomb would be enough to deal with ducting. Dismantling a dashboard sounds like seriously hard work!

[Bongolia]

Is the matrix difficult to access?
I may put it on my to do list.

[CheekyRich]

The Bongo used to be smoked in so I've stripped down most of the vehicle (panels / carpets / seats, the works) and the front ducting is the final part pf the interior to do. I would like to remove the ducting and clean it all through with Meguairs All Puropse Cleaner (APC) - this dissolves the tar residues and the liquid comes off black! Then I would rinse it all through with water before putting it all back. That's what I did with the rear ducting from the rear heater to overhead vents in the back. Trying to do a thorough job on the van as it's a great vehicle that I'd like to keep long-term. It's a 1995 2.5 diesel.

I've got a Dakota bomb
https://www.amazon.co.uk/Dakota-Odor-Bo ... B001UOYNK8
which I haven't used yet - I'm trying to get rid of the tar / dust etc by actually physically removing it rather than trying to mask it. Also it's a good idea to remove any smoke deposits for health reasons.

I've so far followed the logical route to getting the dash out - disconnecting all electrics; removing accessible screws that I'm aware of.. but without a manual I don't know what else has to come out and it still seems to be very firmly fixed in. I don't want to go too far and remove so much that I can't get it all back in again.

Is the matrix difficult to access?
I may put it on my to do list.

There is a guide to matrix accessing here on the "other" forum:
http://www.bongoforum.co.uk/cgi-bin/for ... 334165091/

I think I'm unable to access the heater box / matrix without draining the coolant - this is not practical where the van is kept at the moment so is another job for the future for me.

[mikeonb4c]

To clean the matrix as i did you don't touch the coolant side, you remove the intake and blower fan assembly under the bonnet then pick the mess out with wire, watchmaker screwdriver or whatever plus hoovering. Front dashboard ducting shouldn't be affected by smoke tar really unless they've been setting the system on recirculate a lot while smoking (which seems pretty mad even for a smoker)? Exit ducts at vehicle rear would provide best indicator of ciggie tar build up i'd have thought.

[CheekyRich]

To clean the matrix as i did you don't touch the coolant side, you remove the intake and blower fan assembly under the bonnet then pick the mess out with wire, watchmaker screwdriver or whatever plus hoovering. Front dashboard ducting shouldn't be affected by smoke tar really unless they've been setting the system on recirculate a lot while smoking (which seems pretty mad even for a smoker)? Exit ducts at vehicle rear would provide best indicator of ciggie tar build up i'd have thought.

Whereabouts are the exit ducts?

[mikeonb4c]

To clean the matrix as i did you don't touch the coolant side, you remove the intake and blower fan assembly under the bonnet then pick the mess out with wire, watchmaker screwdriver or whatever plus hoovering. Front dashboard ducting shouldn't be affected by smoke tar really unless they've been setting the system on recirculate a lot while smoking (which seems pretty mad even for a smoker)? Exit ducts at vehicle rear would provide best indicator of ciggie tar build up i'd have thought.

Whereabouts are the exit ducts?

At the back, hidden beneath the rear bumper. I'm guessing but you might be able to inspect them by removing the rear interior trim panels - hopefully someone else on here will know.

[Northern Bongolow]

the exit ducts have plastic/rubber flaps on them and are hidden under the sides of the rear bumper, just behind the rear wheels.

you can see them in this link.

http://igmaynard.co.uk/bongo/forum/view ... 08#p655512

[CheekyRich]

the exit ducts have plastic/rubber flaps on them and are hidden under the sides of the rear bumper, just behind the rear wheels.

you can see them in this link.

http://igmaynard.co.uk/bongo/forum/view ... 08#p655512

Thanks NB - I'll take a look

In the meantime, if anyone in the Bongo community can help with dashboard removal please let me know!

[wonkanoby]

here are 2 write ups i found to give my mechanic when heater in front was done



FIRST ONE


My matrix failed back in the summer and I replaced it with one from a Bongo breakers - check out ebay - there's a few reputable ones out there and should be MUCH cheaper than a new one...

The knack in replacing the front matrix is to loosen all the bolts on the dashboard (finding them is what took the time for me as no written instructions anywhere!) - this allows the dashboard to slide back so the heater box can pull back from the front bulkhead enough that you can pull out the matrix. You have to be careful with the matrix as it has plastic pipes which are easy to break..

The matrix is in the passengers footwell - - it should be easy to see as it has 2 pipes leading into it- there's a plastic cover, remove this. You will then need to take out the bolts holding the heater box to the bulkhead (3 10mm I think). Then you need to loosen the dashboard bolts - take out the plastic covers at each end of the dashboard by levering them out - be careful in the cold as the plastic might break!. Behind these you'll see some 13mm bolts (big ones) - take these out/loosen them. In the centre of the dashboard by the windsreen there's another plastic cover - prise this up and undo the 10mm bolt under it. You will now need to take the side covers off the centre console and you should see some more 13mm bolts there - undo these and the dashboard should be loose (going on memory here). There's plenty of wires etc still connected so gently pull the dashboard back making sure its not snagged on anything (I dont think it will fall but be careful). Now you can drain your coolant, and then take out the front heater box components so the pipes in the "engine" bay to the matrix pipes coming through the bulkhead are exposed - undo them. Now its a case of getting back inside (get some rags handy!), pull back the heater box (should have enough movement now the dash is loose) and the pipes should just clear the bulkhead - pull out the matrix sideways.

... put new matrix in - probably worth reverse flushing it, making sure it doesnt have a leak etc etc. When putting it back in I found it quite a squeeze getting it back into the heater box and then the dash back in with the matrix pipes gently eased into the bulkhead holes... Lots of swearing did the job. Make sure you get all the bolts in, stuff reconnected etc etc.

Dont forget to follow the bleeding instructions on the factsheet (always worked well for me - just wait for the bottom hose to get hot!) or the Youtube videos. Make sure you use a 50% mix of antifreeze - follow threads here on which type - I've used the blue stuff. Realistically, a good afternoons job.. As I just had the Bongo at the time I took the opportunity to do all the major hoses and fit an LCA and Mason alarm too..

Hope this helps!

Steve

SECOND ONE

This is my experience of Replacing The Heater Matrix 1997 Bongo 2.5 Diesel.
Remove the centre consol
Remove the two (triangular) trim panels just in front of the auto changer lever.
Tilt back the seats to expose the engine bay
Remove the bottom hose and drain the coolant in to a container (Container size 15ltrs)
Open the Bonnet
Remove the air scoop for the air con\heater
Remove the top of the fan housing to gain access to the heater matrix hose clips


I marked the top hose of the heater for orientation purposes.

(Optional) Unbolt air con unit and pull forward to see the heater matrix (I did this to make sure the heater was leaking)
Remove ICE system
Remove the cubby box below ICE system

Unbolt the steel mount bracket below the dash which holds electrical units and slide back towards the gear lever

Unscrew the passenger side cover to the heater box to expose the heater

Unbolt the heater box from the inner bulk head and pull the heater box back towards gear lever.
Pull sideways, towards the passenger door, the floor mat and sound deadening material so that the pipes will clear in the next operation
Now how brave are you? Using a suitable lever\pry bar and a piece of 4X2 wood, lever the heater box just enough to clear the pipes from the bulk head and slide the heater out of the box

Clean out the heater box of debris prior to inserting the new heater matrix ( 3 dried Wasps in mine)
Replace in reverse
Fill with coolant and bleed system.

[CheekyRich]

Decided to man up and took out the whole lot including the metal pipe section (the plastic section can't be removed without.) Thought I'd try something outside my comfort zone.
Big job, but mostly psychological having reached this point. Mostly in addition to the above it was removing cables attached to the metal part of the dash, labelling them and removing the cable tidy connectors that insert into holes into the dash / frame.