Hi Big Daddy..
As for the previous head I think, as I recall, I bought it through this website.... But I do remember thinking it looked a lightweight flimsy thing to be sitting on top of thousands of explosions. Albeit small controlled ones.
It was fitted by our local mechanic who is a thorough and well trained guy, and who has repaired and serviced our Bongo since we got it about 7 years ago, always to my satisfaction. This first incident was after some period when we'd had a number of coolant loss problems (water pump, hoses) ultimately it went just as we were to board a ferry to France (so the long laden up trip from Manchester to Portsmouth didn't help. We'd also had an overheating episode on that journey. Anyway I can kind of understand the pressures and strains that would have resulted in a cracked head on this first occasion, which I believe was around May 2007.
With the new head fitted we seem to have enjoyed mostly trouble free motoring in the beast (aside from one curious overheating incident not long after the new head. We stopped on the side of the m6, noticing a dramatic rise on the gau ge) waited a good half hour or so and checked the levels to find find hardely any coolant loss. Topped it up the little that was required then I cant say I can recall an overheating problem since. I believe this incident may have been due to an airlock).
Then, this recent occasion occurred thus.. (I'll admit I hadn't checked the level in the expansion bottle for about a week before the incident. And I had been driving it locally ( say 10-20 miles per day). Ordinarily I would check the oil and water prior to such a trip as on the day it went. (ie a 70 mile round trip on the motorway) but on this occasion to my shame I hadn't. My partner was following me from Manchester to Chester, I in the car (with 2 sons) she in the Bongo (with other son, wife and the 3 grandkids). I got the call that the vehicle was broken down near the M56/M6 junction, and words like 'smoke' 'steam' and 'loss of power' were mentioned.
By the time I had dropped my payload and returned (we were all heading to my mother in law's 70th birthday barbeque) so she could take the car and I return to Manchester with the sick van on a recovery low loader, it became apparent that the bottom radiator hose had split. Back at my place, when we tried to fire up the engine to reverse the vehicle onto my drive it became clear there was a complete lack of compression.
My problem now is, obviously, her, and to a lesser extent, my confidence in and liking for the vehicle have been somewhat impaired by this second expensive repair incident. Another related problem is that, due to a couple of prangs I have had with it (involving reversing into a skip (duh !) and scraping it on a gatepost, .... that although after it has this second head fitted it will be relatively low mileage (c. 100,000 miles) its resale value has been seriouly dented by the, well, in some peoples eyes quite serious dents.
I like the Bongo !! I like the way it looks, and drives, its comfy, esp.. on long trips (we are both 6ft) and I love its multiple functionalities. Also I like the fact that this forum exists to help out owners. Maybe I should have made more use of the site during my several years of membership. One thing we have never liked though is the fuel consumption. But I can excuse this since the vehicle is effectely a van. And a B & B when the need arises. But what I am now vexed about is this coolant achilles heel.. I have tried to look after and maintain the vehicle as best I can (regular servicing and checking levels,. I even undersealed it last year, the body work is in great nick (apart from my dents...) but if I am going to be looking at having to fork out around a grand or more each year on sorting out the cylinder head then it may need to go. What concerns me is that the first incident could perhaps be attributed to carelessness, but this second one has come out of the blue. And I am now starting to think it could well happen again in a year. If the answer, to give me peace of mind, is to need to check the thermostat, replace all the hoses, flush the entire system, fit an audible alarm in the expamsion bottle and never play my music too loud in the cab, well, I guess I could do all these things but it seems rather excessive to be able to enjoy cylinder-head-breakage free motoring. But in my case, with a dented and scratched nearside rear end, it could be my only option.
As a result I don't love our Bongo as much as I used to .
And my missus has developed a dislike for it. Initially the high driving position was one of the reasons we got it (to assist with partner's sciatica) .. It is now causing disagreements in our happy home.
Any suggestions ? (other than the obvious 'stop moaning and try'n drive more carefully (especially in reverse.)). ( or get a different partner) etc etc
??
Sorry for the rant ppl but these 2 x cylinder head jobs will have ended up costing more than I paid for our other car, which is an excellently running Mazda323. Grrrr.
PS we never look at our fuel gauge. Its always been broken. We just make sure to fill up every 250 -300 miles. then press the odo button.
) So, I'd worry not my friend... I'd suggest though that you may want to change your forum name...The other forum member who's head had gone was named after a primate! 
