You Tube video - 1995 Bongo 2.5L WL-T Diesel - New Head

[widdowson2008]

Keep it coming - terrific stuff

[progroup]

Dave - really appreciate you taking the time to do this. Are you planning to film the rebuild?

We were just discussing that.. Rodney and I!

I think so because we have an opportunity starting this Friday & Saturday. I MUST get this BongoBus back on the road or I'll go bongos!

A word to the wise; never combine a camping van, utility van, business van into one vehicle. The BongoBoner has broken me down emotionally, objectively, and I hasen to add, my family think I gone Bongobonkers.

Dave

[widdowson2008]

.........my family think I gone Bongobonkers.
Dave

Wasn't that explained to you when you joined the club?

Being unstable (mentally or otherwise) is a pre-requisite of being a member.

[Kincaid]

.........my family think I gone Bongobonkers.

Ha! mine the same

In one of the films you were just about to tell us how much time you'd spent to get the passenger side clear - what sort of time have you spent on the actual work so far?

[progroup]

.........my family think I gone Bongobonkers.
Dave

Wasn't that explained to you when you joined the club?

Being unstable (mentally or otherwise) is a pre-requisite of being a member.

You know you are right, it was explained afterall... I found Bongo Fury well before I handed 'Rob' baby the cash. Thought it was rather strange how fast he ran away with the wife and all.

I guess all the worldwide support turned me on in some pathetic way. Misery loves company, eh?

[progroup]

.........my family think I gone Bongobonkers.

Ha! mine the same

In one of the films you were just about to tell us how much time you'd spent to get the passenger side clear - what sort of time have you spent on the actual work so far?

About two hours removing the head in general; another hour on the bench to remove delicate stuff. Took most of one day to rebuilt on & off first time. Hardest part initially was reinstalling the timing belt tensioner spring. Needlenose works okay to lift spring onto mounting tab.

I have lost count of the hours overall because this vehicle is new to me. It took about two hours to fully install the tow bar kit; less than two hours for the airlift system [and I still fussed over this one to make it better by shrounding with 'loom' and routing].

I had a local Spring shop make the custom 2"x4" U-Bolts; and another shop to bore four additional holes in the 2" receiver attachment. Both did this work exactly one before our scheduled departure last Friday. I installed the add-on back at home of course.

A Note for Ian; it sure would have made my life easier if those darn manuals had shown up! We are in the midst of a national postal strike; so Canada Post will take weeks and weeks for me to finally receive if ever. If there is a next time; I will pay the shipping via Interparcel a.k.a. UPD/DHL/FedEX. I received my first cylinder head within 2 days! That's 20kgs for 83GBP! The replacement head is scheduled for delivery this Friday as it was shipped yesterday.

More on this later...

[progroup]

Okay Folks; BongoBonnie is back up running just fine!

I did manage to film the re-installation and will post on You Tube later.

The engine runs so so quiet now; not like a bunch a bolts as before.

There must be an easier way to bleed the coolant system. On Mazda's production line, you can't convince me that it took two mor three technicians, a funnel, and over 40 minutes to evacuate air from the engine. My pressure method didn't work by the way!

But in the end, I adopted Hayden & MissFixit70's arduous approach to the problem. At least for now!

I still maintain though, compared to many other vehicles I've worked on, the Bongo is fairly easy. Beleive me, far easier than many under the hood conventional powertrains.