Bongo Fury

hi all, I've got a 2.5 4wd -with 78000 checked mileage.

The van has had a new head in march (before i bought it) from a decent garage, but you can tell it boiled as the exapnsion tank is the lovely dark tea colour. All the hoses are looking a bit tired, although not knackered and the belts are ok (no cracks etc), but could do with replacing.

I have some spare cash (is there such a thing? ) and am contemplating a complete cooling system rebuild (gulp)

Below is a list if bits i think I'm going to need:
new rad - current one has lots of dings and dead flies + seems ab it cooler at the bottom when its up to temp
new water pump
new belts
new hoses (all of em) - probably the silicon type (is there a real difference between these and the normal ones?)
new thermostat
new clips
coolant (obviously!)
new header tank
i already have a Mason alarm

is there anything else i need? I'm sure i've forgotten something...should i do a 2 part flush of the engine as well? Also what type of thing should i look out for post operation as it were (hoses clips tightening etc etc)

Also, I have a local garage to me that sells and repairs bongos (GP motor works in Bembridge, Isle of Wight) that I'm gonna get to do most of it - what i'm after is how long something of this nature would take? I propose to get my hands dirty and help out (so i can learn the subtle nuances of the bongo cooling system) but would like a vague timescale form someone who has done this type of work before.

Thanks - i'll keep you updated as the project goes along.....

I have just purchased a TM2 combined temp/coolant alarm and if it ever stops p*ssing with rain hopefully I can fit it tomorrow.
The more I read the on the forum the more paranoid I feel about the dreaded head cooking potential, which takes the edge off the overall pleasure we get from the Bongo.

I have also thought about a complete cooling system re-fit and will be very interested to hear how much it's likely to cost, and what other suggestions come from others.

Anyway it's good to hear that the IOW has escaped the credit crunch.

the IOW is probably the worst hit by the credit crunch - lots of unemployment at the mo...but i only live there - i commute of the island to earn some 'real' money

the bits so far arou hovering around the £600 mark ( an new expansion tank from mazda is around £120 )

as for the man hours - that's the bit i'm really after....

I've just spent the best part of 3 days under our bongo sorting out a leak and I'm attempting a coolant flush and bleed tomorrrow along with a new thermo. I've learnt a hell of a lot about the system and its little quirks as well as the dreaded air locks!.......I'm tempted to say, If it ain't broke don't fix it!!!.....

true - i know what you mean, but i never found out why it boiled - hoses, gasket? so although its had a new head the hoses are probably the original ones, the waterpump looks original and the rad is pretty buggered, so i keep thinking paranoid thoughts

You do seem a bit concerned about cooling problems and seem to be looking at the 'prevention is better than cure' route, rather than 'if it aint broke don't fix it'. Allan replaced a lot (on our Freda) due to necessity when the head went. He renewed everything that needed renewing at that time, but nothing that didn't.
The parts that needed renewing included the head, head gasket, valves, water pump, radiator, thermostat, 4 main hoses (mazda ones, not silicone - it's easier for us and we thought if the last mazda set lasted for over 100,000 miles they must be OK), coolant, water elbow, dowel pin and spring. He also replaced the cambelt and tensioner, adjusted the tappets and fitted a new fan switch on the head.

the rad is pretty buggered, so i keep thinking paranoid thoughts

If you do nothing else, do sort the rad!
If the header tank is functional (but discoloured) you can save money by not replacing it as you can still read the level with a stick, see this advice from Haydn

Get yourself a "lolly" stick. Draw a line on it 1.5 cms from one end. Put the stick down the neck of the tank as vertical as possible and untill it touches the bottom. The coolant should be at the level marked on the stick.

If you don't know when the cambelt was replaced, you could put the money towards that - it's obviously not part of the cooling system but may need attention and shouldn't be overlooked.

if your going to that extent then inspect the metal pipes as well

that join rad to engine

the main one drivers side on mine leaked not long ago

in one place after another after temporary fixes

A good balance of opinions on here.

Personally, I bought mine 2 years ago, with an overheating fault We fixed what needed to be done at the time, including new head, pump, stat & cambelt. Have since replaced hoses as & when. Still has a brown header tank & 10 twelve year old hoses but it seems to be solid so I'm happy with that. But to be honest, if I had that elusive spare cash, I'd do the same meself.


Peace of Mind - Priceless.

I've (Allan) has just recently replaced rad and couple of hoses and did not do the thermostat at the same time which he has just done and now all is running much cooler and much more stable at the top end temps on big hills.

I would not do anything that did not need doing - it the water pump is ok then leave it, same goes for the expansion tank - save your money and get a TM2 or a low coolant alarm fitted to go with the Mason alarm.

But I can see the attraction of doing everything if money is no object...

We've just had a new head, cam belt, stat, hoses and rad done. The pump was ok but should I have changed it any way.................

The extra labour on top of the head quote was about 4 hours for the hose and rads.

hi all, thanks for all your advice - both sides of the fence voiced : )

I agree that if it aint broke don't fix it, but it defo needs a new rad - maybe i'll do the four main hoses as well. It had the cambelt done in april + a few other bits, so that should be ok.

I'm going to get it over an inspection pit at the weekend and have a good poke around all the nooks and crannies - that way i can see all those little hard to get to hoses and connectors : )

jed1y0da wrote:
I'm going to get it over an inspection pit at the weekend and have a good poke around all the nooks and crannies - that way i can see all those little hard to get to hoses and connectors : )

that is if it doesn't rain.....

Best bet is to get some UV dye and then check for leaks that way.
Speaking from experience check the core plugs for signs of rust as well.

i was looking at the coolant alarm etc, but every bongo own i've come across i've asked do you have one fitted? if so can i see it? so i can see where it fits and how it works. i have not found anyone in my area who has had one fitted even one guy has had his bongo for like 6 years never does anything with it even down to changing the oil, which i know seems madness. now i'm still looking at getting these units but what i don't get is if they are that important why can i not find anyone with one i can look at
if anyone lives local that has one whats to meet up, so i can see if running on their bongo I'd be more than happy.

jed1y0da wrote: Below is a list if bits i think I'm going to need:
new rad - current one has lots of dings and dead flies + seems ab it cooler at the bottom when its up to temp

Hi jed1y0da,

I'll tell you what i found with the rad mine can seem that way after a trip..
By all accounts normal due to air cooling & fans..
But if you put the pre ignition on without starting then run yer hand the hight of the rad it should warm all over!

Then again.. If your rad IS blocked go for a new one!

Gerriatric wrote:I have just purchased a TM2 combined temp/coolant alarm and if it ever stops p*ssing with rain hopefully I can fit it tomorrow.
The more I read the on the forum the more paranoid I feel about the dreaded head cooking potential, which takes the edge off the overall pleasure we get from the Bongo.

I have also thought about a complete cooling system re-fit and will be very interested to hear how much it's likely to cost, and what other suggestions come from others.

Anyway it's good to hear that the IOW has escaped the credit crunch.

Hey Gerry, where in Corsham are ya?
Is that you that visits Box in a green aft & parks down Bulls lane occasionally?
Or the silver one i see outside the Hair & Hounds, Corsham, on the corner of the road going through to Pickwick?
I know what you mean about the rain...