Bongo Fury

I'm following the members' factsheets to fit an Eberspacher D2 in the engine bay, underneath the passenger seat.

My Bongo is 2.5 diesel late 1999—the newer shape—with the winter pack. However when I compare my engine bay to the photo in the factsheet, the gubbins to do with the turbo aren't there.

I suppose that's a good thing as it should be easier to make way for the Eberspacher, but I'm not 100% sure what it's safe to remove.

I'd be grateful if someone in the know could take a look at these pics and tell me what these bits are, what can be taken out, and what needs to be repositioned.

all that is shown to the lower side of the chassis member can be removed, this is the control system for the winter model exhaust restrictor valve assembly, your bongo looks like a northern jap winter model it should have a switch by your right knee with an engine symbol on it when sat in the drivers seat and a big lump in the exhaust between the first section and the second section. this is switch closed when its really cold and partly blocks the exhaust to assist in engine warm up. its not really needed in the uk but i liked to use mine, you may also like to keep yours living where you do.

simply block the air pipes and move the lecky bits. leave the little oblong block that is bolted to the top of the chassis leg where it is. some remove the valve on the exhaust and replace the section with a standard system exhaust.

http://lushprojects.com/bongopartsmk2/c ... mgno=.html

http://lushprojects.com/bongopartsmk2/c ... 2of02.html.

this is your exhaust, note the shorter first pipe and valve .
http://lushprojects.com/bongopartsmk2/c ... 1of02.html

Thanks, NB—very helpful.

I do have the engine symbol switch, but my exhaust has been completely replaced over the last couple of years and the bit you're referring to was replaced with the standard section. So I'll strip those other bits out and leave the electric bits be.

make sure you blank the vac pipes off or you will loose vac to the other things like cold start solenoids which you will still need.

So the two pipes to be blanked off are the very thin one which disappears off to the left of my photo above, and the wider upright one just above the chassis member? Those are the only two left after removing the assembly below the chassis member in my photos.

Presumably I can bend and crimp the smaller one back on itself? The larger I guess I can get a blanking cap for?

I’ve also moved the “oblong block” (incidentally would love to know what that thing actually is!) about 3 inches to the right, where there was an empty bolt hole. That’s given me much more room for the bracket I’ve made to hold the heater.

You can make blanks with a bit of m6 bar and a cable tie.

My Webasto lives there and vents into cabin from bottom of centre panel between seats, near to the rear floor. It's so good in the winter lol.

the metal thin one is the important one as it is a vac pipe coming from the vac pump so make sure its airtight. i would push on some small dia rubber pipe then fit a bung, use clips if ness.