Bongo Fury

Hello everyone,

Can anyone tell me the easiest way to take out the engine of my bongo


Cheers Wayne

I would imagine it will have to come out from underneath Wayne.So you are gonna need a ramp etc etc.
Dabs

as dave said, got to drop it out of the bottom

Hi waycar

I've recently done an engine swap. I really wanted to lift it up and out of the door using an engine crane, however I looked very closely at the logistics of doing this and it really didn't sseem practical at all. THe engine is just to big and the hole is just too small.

Ideally, you want a garage lift and engine crane, bu tif you're skint and without workshop facilities like moi, read on:

So, this is what I did. I'm not a mechanic or fitter so don't assume this is the right way at all..it just worked for me:

1. Lifted the rear of van with jacks and built brick piers with a paving slab on top 3 bricks high and lowered van back on to these. This gives enough access underneath to disconnect back drive shaft and gearbox moutings.

2. Raised front of vehicle on axle stands to give enough clearance to disconnect everything.

3. Disconnected front drive shaft and everything from the engine, and left it so the only thing keeping it in was the 4 bolts holding engine cradel to chassis.

4. Supported the gearbox on 2 trolley jacks with wood platforms on top. Disconnnected rear drive shaft, gearbox mounting bolt and bell housing bolts, then pullled the gear box rearwards on the jacks until the bell housing had cleared the torque converter, then lowered it down and out of the way.

5. Just crack the 4 engine cradle mouting bolts to make them easier to undo later.

6. Jacked the front of the van up gradually with a trolley jack in centre and gradually built brick piers under the axle stands, with a 3rd brick pier under the jack as it ran out of lift height. You need to lift the van up to give a 700mm clearance........this is quite scary, and a better/safer lifting method would be desirable if you can think of one. But since you don't need to be under the van at all at this height it's not too risky. You do need a lot of bricks which I happen to have!

7. Hired and engine crane from HSS (£30), and borrowed some chains and shackles and poked the crane in through the side door. Shackled 4 chains rated 250kg each to the engine mounting cradle and took the weight. Undid the 4 mounting bolts and then lowered the engine onto a skate and slid it out of the side. It's a tall engine so measure and plan carefully. And DO make sure your liftig chains are strong enough for the weight of the engine.

7A.Take the opportunity to renew any dodgy hoses and pipes, thermostat and cam belt if new engine is s/h while engine is out.

8. Using the crane, lift the old engine off the skate and onto a pallet, and lift the new engine onto the skate. Roll underneath the van.

9. Lower van to safe working height but allowing clearance to connect everything. It must be safely supported as you will be underneath for a long time!

10. Attach crane and chains to engine, then lift into position, but don't fit the bolts yet.

11. Lift the gearbox and transfer box on trolley jacks and mate the engine to the bellhousing ensuring everything is well lined up.....this is the most difficult part of the process, so take your time. You want to be able to lower and lift the engine a bit and be able to swing it on the crane a little to make life easier. When engine/gearbox is connected lift both together bit by bit until the top gearbox mounting is well lined up then stick in the bolt and tighten it.

12. Fit and tighten the 4 engine cradle mounting bolts.

13. Reconnect everything.

14. Fill with oil to correct level.

15. Ensure new engine starts and revs freely before filling with coolant, just for a few moments though......won't do any harm.

16. Fill coolant and bleed carefully.

17. Once you're sure everything is ok, lower vehicle and drive away with warm smug feeling of satisfaction.


This is the experience of a non-mechanic so will probably make all mechanics suck air in through clenched teeth, however, just plan the operation very carefully and try to identify all potential problems before you start. For sure make sure the van is in the right palce to start with allowing enough space to allow access for engine crane, and to roll out old engine etc.
When working underneath and lifting/lowering van, engine and gearbox, think and be certain before starting anything that there is absolutely no danger to you or anyone else in what you're doing.

Hopefully you'll have access to a more professional method than me but at least be assured that it is possible to do it with just a driveway and
regular tools.

Good luck

Rob

PS:Feel free to pm me if you need any specific details.

I'm come over all of a quiver just reading that. Way out of my league esp. with my recent 'back' episodes. Bl**dy heroic stuff as fas as I'm concerned.

Rob has stated it plainly anyway, but do be careful Wayne. You're much more important than a Bongo engine. Good luck

Thanks for all the replys everyone, especially Rob

thats the response i was after, i can borrow a engine crane, + i have a pair of ramps and axle stands,(but i dont think they will be big enough ), but i do have a big pile of bricks

That seems a great way of dropping/re fitting a bongo engine....Thanks Rob for all that Good man.

I dont think wayne has to put another engine in though rob...I assume you have a potential buyer for the engine in your trashed bongo wayne?

I think you should replace your broken green bongo with a nice white one

bigdaddycain wrote:That seems a great way of dropping/re fitting a bongo engine....Thanks Rob for all that Good man.

I dont think wayne has to put another engine in though rob...I assume you have a potential buyer for the engine in your trashed bongo wayne?:

no just need to get the engine out, i think i may get my grinder out and cut away all the floor around the engine and lift it out seeing as mine scrap

bigdaddycain wrote:I think you should replace your broken green bongo with a nice white one

hmmn good thinking i may buy a white one, if i can find one at the right price

It may be an idea if you coul get hold of one of those airbag lift thingies that recovery firms have,then you could cut out the engine (after incorporating an axle stand or two to take the weight) then slowly lift the bongo onto its two wheels then slide the engine out sideways...

No worries about high sided vehicles toppling over

http://www.youtube.com/watch?v=tpSEaeiV4z8

wayne just a min mate if you cant get bongo high enough to remove engine couldnt you get the engine to the ground with the lift then take lift off engine and attach to bongo and lift bongo off engine ?
i know these lifts lift at least 2 ton




you've been bongod

You've Been Bongod wrote:wayne just a min mate if you cant get bongo high enough to remove engine couldnt you get the engine to the ground with the lift then take lift off engine and attach to bongo and lift bongo off engine ?
i know these lifts lift at least 2 ton




you've been bongod

My drive is on a steep slant down towards house so its a bit of a gamble

Anyone know what sort of price to ask for an auto box, in good working order?

put handbrake on !!!!!!!!!!!!!!!!!!!!!!!!!!

good earbox 4wd?

should be worth at least £100


you've been bongod

If you`ve got access to a grinder why not cut out the front panel and the bulkhead and then release the engine and box and push the van backwards - just an idea or I may be talking out of my..........

waycar8 wrote:
Anyone know what sort of price to ask for an auto box, in good working order?

Half a bag of sand at least i'd have thought Wayne... Auto boxes ain't cheap!

I paid £800 for a "cheapie" reconditioned auto box for my scorpio cosworth...and that was about ten years ago!