Bongo Fury

A bit of a newbie (and probably daft) question regarding exhausts (1999 2.5L TD). Can the exhaust replacement parts be supplied by the standard exhaust replacement/fitting places or is it a matter of buying bits myself from the shop and providing that to them? Or is it really a job for a more specialised garage? I am in Inverness if that's useful.

The middle part (with flexi) had just died and I need at least that and bolts/gaskets. I may also need more as the joints look quite corroded (compared to the pipes!).

Thanks for any help.

Fitting isn't a specialist job, can be done by any mechanic including DIY.
Hopefully somebody else will have experience with exhaust replacement centres, personally I'm not a fan and have done the Bongo myself. The following may be helpful either if ordering yourself or for making sure a non-bongo specialist gets the right things.

Mid section (with the flexi bit) and tail pipe are same across diesel Bongos so straightforward. Crush washers between each joint.
Down pipe varies:
If you have a cold weather option on your Bongo you have a short downpipe, then the cold weather gubbins which joins with the flexi section. (Left hand pipe in photo)
If you don't have the cold weather option , a longer downpipe joins the flexi section (Right hand pipe in photo).



The slightly unusual bit will be if the dodgy joint affects the section with the cold weather kit. Rather than bother you with the options unnecessarily, let us know if this is relevant to you i.e. do you have a cold weather kit and are its flanges blowing?

Hi, sorry for thread hijack...
Can peoplw tell me what gasket i need for the downpipe? I can't see one that says catagorically that it is for the downpipe piece (engine end, with three studs). Or is this gasket the same as further down the exhaust?
I have a second hand SS exhaust to fit soon and it only requires that one gasket as the other join is just a sleeve fit.

Have found it an easy diy job for middle and back boxes, with decent tools (ramps) and gaskets+replacement bolts in case old ones are corroded and providing old ones aren't seized on. Parts cheap off ebay, probably over pricey if exhaust fitters order them in.

cmm303 wrote:The slightly unusual bit will be if the dodgy joint affects the section with the cold weather kit. Rather than bother you with the options unnecessarily, let us know if this is relevant to you i.e. do you have a cold weather kit and are its flanges blowing?

Yes, it's a cold weather Bongo with the winter pack I have.

The flanges on both sides of the exhaust valve are very corroded, the bolts look very bad too. They probably are the worst along the full exhaust. So I was wondering whether to get the whole exhaust replaced by a fitter and remove the winter pack at the same time.

If I understand well, the vacuum hose at the valve would need capped and the electrics isolated (until I get the gubbins under the passenger seat sorted) and a standard downpipe could be fitted instead. Is that right?

Thanks for the help so far. Below is a (fairly scary) photo of the connections around the exhaust valve of the winter pack... My immediate problem is not here but at the flexi pipe. Nonetheless I wonder whether to replace everything anyway given the amount of corrosion. I'm also worried of future issues with the valve, should I just be fitting a 3 pipe (non winter kit) exhaust?

I have a very similar looking winter valve and have the parts to remove and install the 3 part exhaust. It was just too wet at the weekend to fit but I'm bouyed by the comments of it being an easy DIY job!

I had photos of both 3 and 4 piece systems side by side because I ditched my non-serviceable winter pack, replacing with a long downpipe. I sourced a used down pipe from Bongospares but worth checking against the cost of new.
I'd isolate the vacuum feed to the winter pack underneath the passy seat where it goes into the controlling mechanism from a metal vacuum pipe coming from the front of the engine bay. Vacuum pipe cap ends can be bought off eBay, or plug the rubber pipe.

I recall struggling with the bolts on the tail pipe section. Couple of days of penetrating oil squirts help!
I used "crush" washers when assembling all joints including engine end of downpipe. (Supplied I think by Bongospares but they must be readily available.) Later found that this forward end of the downpipe was blowing slightly because I had not cleaned off the old sealant remnants from the turbo elbow. So I'd recommend cleaning with a small wire brush on a Dremel if possible and use some exhaust sealant on reassembly. All other joints are easy to prepare and have been fine assembled "dry" with the new washers.
As already said, there is working space with the passy side popped up a few inches on ramps (Usual safety precautions taken).
Warm new rubber hangers in boiling water to make them easier to put on.

cmm303 wrote: I'd isolate the vacuum feed to the winter pack underneath the passy seat where it goes into the controlling mechanism from a metal vacuum pipe coming from the front of the engine bay. Vacuum pipe cap ends can be bought off eBay, or plug the rubber pipe.

Do you happen to know what size cap/plug is required? I would like to get ordered ready for the job but haven't been able to confirm. Thanks

roosmith wrote:

cmm303 wrote: I'd isolate the vacuum feed to the winter pack underneath the passy seat where it goes into the controlling mechanism from a metal vacuum pipe coming from the front of the engine bay. Vacuum pipe cap ends can be bought off eBay, or plug the rubber pipe.

Do you happen to know what size cap/plug is required? I would like to get ordered ready for the job but haven't been able to confirm. Thanks

Plastic ruler measurement of metal pipe sitting in my garage: 4mm external dia. That is the straight bit, the swaged end is larger. If they are cheap, I would also buy 1mm either way.

Spot on, thank you

callum wrote:Hi, sorry for thread hijack...
Can peoplw tell me what gasket i need for the downpipe? I can't see one that says catagorically that it is for the downpipe piece (engine end, with three studs). Or is this gasket the same as further down the exhaust?
I have a second hand SS exhaust to fit soon and it only requires that one gasket as the other join is just a sleeve fit.

I used these throughout. Recommend a bit of paste on turbo downpipe joint because access makes it harder to clean up this joint as thoroughly.

As an update to my original post, Dingwall Tyres (http://www.dingwalltyrescentre.co.uk/) managed to source the flexi part of the exhaust overnight and fit for a very reasonable cost. So I just went along with them in the end.

I will still attempt to remove the winter pack valve as a DYI job later this summer when I have more time I think.

jprenaud wrote:As an update to my original post, Dingwall Tyres (http://www.dingwalltyrescentre.co.uk/) managed to source the flexi part of the exhaust overnight and fit for a very reasonable cost. So I just went along with them in the end.

I will still attempt to remove the winter pack valve as a DYI job later this summer when I have more time I think.

Excellent. If you like the fitters and if they are happy to tackle the other stuff, i'd be tempted to let them do it. My reference to easy DIY are limited to having done middle and back sections on my non winter pack Bongo.