Bongo Fury

Hi

I have a 1997 Bongo which I've owned 10 months

KD-SGL5 2.5 TD 4WD

It has developed a rattle.
Oil level OK
Coolant level ok
Thought alternator but putting lights & air con didn't seem to make a difference
Turning wheels full lock didn't change either
Seems worse at tickover and sometimes (rarely though you dont hear it)
video can be found here

http://youtu.be/bIiSBujiN34

I'm no mechanic so will take it somewhere but would be interested in ideas as to what could be the problem. Anyone know of a Bongo friendly garage in the Ipswich Suffolk area?

Cheers

John

Do you have your aircon switched on?

it may be the pump cutting in and out, you may have low aircon fluid level.

Feel free to shoot me down anyone if im wrong!!

Hi

Thanks for the reply try Aircon Off/On and no difference

I forgot to metion it does seem to be smoking quite a bit

Cheers

I don't know if it is the same but my 1995 diesel Bongo developed a hard to define rattle which was more often than not always there at tick over but sometimes not as bad or not noticeable when being driven. I at first suspected alternator but the rattle didn't seem to increase much in speed or intensity when the engine was revved. The performance, speedwise or fuel consumption wise was not affected. I took the Bongo to Wheelquick for a few jobs to be done, when I pulled up outside their place Mick heard the noise and came running out. They said they had never heard a rattle like it and so would try to trace it before doing any work in case it turned out expensive.

In the end it turned out to be the bottom pulley which is in two parts, one part running two belts for the alternator and power steering and the other part for the aircon. It would seem that the two parts are pressed together with a thin rubber sleeve between them to allow some slip so that when the aircon is switched on the two parts of the pulleys don't grab and snap the belts. The rubber insert had worn on mine and was allowing the inside part of the pulley to rattle against the engine casing. This bottom pulley is a heavy lump of metal to be flying around out of balance and could I suppose do some damage if not corrected.. Fortunately for me Wheelquick had a second hand unit and my Bongo is now back to its nice quiet running, when I turn the hearing aid down anyway.

It may not be the same problem with yours but may be worth dropping the belts off to see if there is any excessive play there in the two parts of that pulley. It wouldn't explain the smoke though. Good luck with finding that it is a cheap fix

Bongorattle wrote: I forgot to mention it does seem to be smoking quite a bit

Cheers

Cut down on it's cigarette ration
Seriously, what colour is the smoke and when is it doing it? The causes are many and depend on the colour of the smoke. Also, does it only smoke when first started or all the time?

Thanks Tessie

I'll try and have a look at that bottom pulley. I'll also mention it to the place I'm expecting to take it to.

Thanks John

Black smoke when first started.

Cheers

John

remove the tin shield over the exhaust manifold and check the nuts, manifold to the head. these appear ok til you put a spanner on them, they may have snapped. look for sooty deposits round the manifold/gasket. no1 at the alternator is very prone to snapping.
agree with the crank pulley also, .
the alternator is also a replacement part not a gen mazda, this may be suspect.

Ditto above - sounds like an exhaust blow past number 1 stud to my ol' lugs.

Waterpump bearing ?

just had to change mine as it was rumbling, easy to check, just slacken off the alternator belts
then grab the stationary pump pulley and see if theres any play etc

worked for me

had similar with water pump when the vanes snapped of inside

Just picked up the Bongo and it turned out to be the aux belts gone hard. The worst thing was when I took it to Steve at Outback Autos (long trip) the damn rattle went away...........

Anyway I left it with him an it eventually came back so he could find it. He also found the turbo coolant hoses had deterioated with a small pin hole so those where replaced as well. Great service from Outback Autos and the Bongo is now back and running a treat!

Thanks again for the replies!