2.5td engine out

[Batesy86]

Hi all,

I recently joined the bongo gang on the cheap. I’ve purchased a non-runner with suspected head gasket fault but it turns out to be a split cylinder wall on pot 4.

I’ve stripped off the head and dropped the gearbox to the ground, and I’m now at the stage ready to rip the bottom end out of the van ready for swapping....however, I was wondering if anyone knows if the bottom end (cylinder block) can be lifted out through the cab with an engine crane? It’s stripped as far as possible to make it small enough, but just wondered if anyone had attempted this before I make a right 34DD of myself

My last port of call will be dropping it on the floor and lifting the van up, but that seems a bit precarious to me...especially as I’m doing all this on my drive!

Any help, guidance or pointers are more than appreciated.

Many thanks,

Nick

[Bob]

Hi

I've only seen it done by lifting the body up, but that's whole engines so someone may well know if you can get a stripped one out from inside.

Well done preserving a Bongo.

[Batesy86]

Thanks for the reply Bob.

Do you know how high the van is lifted when taking a whole engine out (roughly)? I’ve only got small basic axle stands and a 2T jack so I think I may struggle.

If no one else has done it I may have to persevere and knock together a little write up...if it works

Gotta save them, plus with all that’s going on I don’t want adventures with the kids to suffer. And what better truck to do it in

[Bob]

Sorry, I've only seen it in a workshop where the body was lifted well clear, I'm not sure what the minimum lift would be.

Whatever you do, be safe.

Here's a cautionary tale from a few years ago:

viewtopic.php?f=2&t=74436&p=699025&hili ... go#p699025

[willow2u]

Get 4 old wheels,Tyres and pieces of timber then jack up front incrementally packing each time with timber until you end up with 2 wheels under each front wheel it’s very stable and that will be plenty

[Batesy86]

Thats what I’m worried about Bob! Be just my luck.

Good shout willow2u, I’ve got a few spare wheels so will give that a go. At that height would I be able to slide a complete engine back under?

[g8dhe]

Someone recently dropped a Bongo on his face multiple fractures, not to be recommended, from FB; https://www.facebook.com/groups/MazdaBo ... 4378810733

[willow2u]

Yes connect gearbox as well it’s so much more easier. Leave ancillaries of so you can tilt engine over once you clear the sill line the height gets better. Are you just going to source complete engine, half engine or rebuild with different block

[rita]

Personally I would drop the engine to the floor first then raise the vehicle. If you are on your drive way put a skid board down first .

And it will be a lot lighter to lift the body without the engine and gear box.

[willow2u]

If you have access to a hoist take weight of engine then remove xmember mounting and lower engine on floor if not a stought piece of timber across engine bay with ratchet strap webbing tied of with a sliding knot so engine can be lowered to floor. I used a mechanics creeper to slide engine and gearbox back in

[willow2u]

But defo lower engine first then jack up

[Batesy86]

Thanks all for your responses!

I’ve got a new block and pistons that I’m going to swap everything that’s serviceable and in good condition over to. I’ll pretty much have a brand new engine unit once complete.

I’ve got a few bits of surface rust (fingers crossed that’s all it is) so I’m going to hammertoe & waxoyl while it’s gutted. Got plenty to keep me busy!

Think I’ll give the drop to the floor and lift the van option then, I really want to rebuild it and time it etc in the garage and then sling it back in so it seems the only logical way.
I do love the old Japanese stuff though, built for the tinkerer!

Has anyone got any info on best way to service the auto gearbox? Or is it a truly specialist job?

[willow2u]

Probably just oil and filter once it’s back in and running

[Batesy86]

Quick update. Engine & gearbox are out...took some head scratching to be able to lift the van high enough as i didn’t have enough wood to chock under wheels etc but I got there.

I’m stripping the engine down and am stuck on the fluid flywheel/viscous coupling (see pic, if it works!) has anyone got any pointers on how to remove this?
It looks like the mounting bolts should be undone from where the starter motor was mounted but either I’m being to simple or I need a special socket as I can’t get any of mine in there?

[willow2u]

Generally you leave torque converter attached in gearbox bell housing there’s 3 or 4 bolts holding it on which you undo from engine side through an access hole covered by a plate I think