Bongo Fury

Afternoon all. I'm an amateur mechanic/soldier who is currently trying to work out whats wrong with my friends bongo. He took it to a garage after head gasket failure and had a new head fitted. The tappets sound horrendous. I have adjusted them up to 0.1 and 0.2 and has made no difference. Sounds like the tappets are going to come through the cam cover. Quite a simple looking head but what on earth is causing this rattle? Do where the tappets rest on wear out?they have a lot of sideways movement!orr thinking maybe related to the fuel timing. Anyone have any experience of this? The rattle increases with the speed of the engine!
Thanks in advance.
A very confused spen!

I think I would start by setting up and checking the timing first ,if the heads been of they may have timed it up wrongly,you've not stated if it's lumpy or smokey. Also is it hard to start ? Is there a lack of power ,some or all inc noises as you've indicated can come from incorrect timing of an engine,keep us up to date .if it's miss timed might be worth getting the rairer involved incase of valve damage!due to miss timed !

Thanks for the swift reply.not lumpy and no more smokey than an old diesel but noise is outrageous. Also slight fuel leak coming from number 1 injector

Check timing first
Meant to read on previous post ,if timing is out get the repairer involved don't touch or alter ought

This one started as intermittent tapping and ended up as replacement engine but there's some useful hints a part of the fault finding process:

http://www.igmaynard.co.uk/bongo/forum/ ... it=+Rocker
http://www.igmaynard.co.uk/bongo/forum/ ... ilit=+Head

Yup timming out by a tooth. Just rung the owner and hes not interested in pursuing the 'mechanic' who done it. Trouble now is i dont have a crank socket big enough so going shopping.going to time correctly and keep fingers crossed before stripping the head in hunt of bent valves

Closer look im not so sure. It's bloody hard to tell using mirrors. Going to reset anyway. It's there any locking tools to make life easier than using mirrors?

http://vid265.photobucket.com/albums/ii ... 115836.mp4

Timing is ok above is a quick video of the noise

That's the injection pump that's noisy as far as I'm concerned.sounds like internal failure of bearing/s
Has it had petrol or veg oil through it ?
Get a steel rod or longish screwdriver or a ratchet 12inch extension lay it on top of inj pump with engine running and use it like a stethoscope and trace the noise ,my gutt instinct is pump

That is kind of my thinking. Not a diesel expert but sounds like it's running out of time which could be down to a knackered pump. If the pump is dead is it a horrendous job to change it?

Not to bad if Simon Jones reads this he's a wizard at post diagrams on how to do this I'd imagine,a recon pump as mines was cost me £450'but you could get a second hand unit if this is the prob from various breakers of bongo (step up Simon or ade) with various contacts ,but tether stethoscope procedure and you should be able toiling fault

its hard to be sure from the vid but half way long the passy side of the rocker cover is a 20mm(ish) pipe, pull it off and have a listen, or even take off the rocker cover, it sounds like a snapped camshaft or broken tappet/rocker. check the camshaft carefully as they can break under the bearings, especially if the heads not right, seen a few snapped into 3 pieces and still running.

it could be the pump timing out as suggested by the injector leaking.slacken the pump mounts off and tip the pump towards you or away and see if that affects it.
if the pump needs a change try http://www.bongospares.co.uk/ he does very good quality recons off the shelf. its only a 2 hour job to swap over as you leave the internal timing gear in situ, just loosen the mounts, cover,belt and the front pulley then tap it backwards minding the key.

just had another look at the vid.

what age is the bongo??.

the rocker cover isnt bolted down.

the vacuum system looks incomplete.

the fuel pump doesnt look standard on the top, the vac advance is missing and the throttle position sensor looks like its been modified.

the glow pug rail is touching the return fuel link pipe from the injectors (next to the front injector).

Thanks for the replies. Its a 96 and i have left bolts off cam cover as going to fit a new gasket. The vacuums etc i have no idea that is how it came to me. Would these make it rattle?

Hi i think with 99 percent conviction say it's the pump. The cam cover is silent and when i use my extension on the pump it sounds like a couple of bolts are going around in there. Looks like it has been done recently too. Am i right in thinking that you can have them tested when removed before splashing out on another one or is it cheaper and easier to buta recon unit?