Bongo Fury

Does anyone know where I can download or gain online access to Bongo service manual.
I cannot find a copy in time for the rebuilt head job I am doing.
Some of the build info needed is reinstalling the timing belt while lining up the cam & injector gears.

Also, I'll need to clean and reassemble the injectors; so any advice or tips on these would be greatly appreciated.
This is the first and only Bongo in Canada so I am a bit in the dark on specific engine references.

All the parts I ordered should be shipped sometime Tuesday. But I've got between then and next week as a buffer to get a service manual if one still exists.

Help Help

Dave

As far as I know Ian sells a service manual with some info in, ask him if it has what you need. There are also fact sheets in the members area that may help.

I seem to remember a site in New Zealand where, for a few dollars, you could download parts of the manual - can't find it now though

francophile1947 wrote:I seem to remember a site in New Zealand where, for a few dollars, you could download parts of the manual - can't find it now though

Always helpful John

pump/injectors are directly driven from crank and aligned with a woodruff locating key,if your taking your head off, why are you taking pump off?? the lower pulley thats in front of the pump DOESNT drive the pump, thats fixed to the same gearing and drives the cam, put the engine/cam in TDC (using 36mm socket on crank nut) and look at the crank pulley, it has a pointer, the drive pulley (fuel pump) has a marker about 10 o'clock and the cam is at 12,mark them all up and ur done.

The injectors are basic mechanical spring relief type pull 1 apart there's nothing intricate inside,still do it carefully tho!

Julian

dandemann8 wrote:

francophile1947 wrote:I seem to remember a site in New Zealand where, for a few dollars, you could download parts of the manual - can't find it now though

Always helpful John

Yep but, hopefully, somebody else might remember it and post

I found serveral examples online [eBay & Amazon]; but even the publisher 'JPNZ' didn't offer the manual at this time.
I'll keep trying; but in light of the fact that I am re-assembling the head to the block, is there chance someone might access their own copy and PDF the details back to me?

It is difficult to access the 'front' motor section and thus particularly difficult to align the cam to injector gear. Do I do this w/mirrors upside down??

Hey Haydyn; I like the coolant sensor mod you produce. We use an exhaust gas measurment as well, a 'pyrometer' I believe. I think one of your exampled products has the same metering option. But I am watching my budget now because of the recent expenditures totalling over half what I paid for the vehicle.

Do you or anyone else have any easily sharable specs on engine oil pressure limits, normal operating temperature, boost or vacumm mods, injector tweaks?

Nearly thirty years ago I used to specialize in Roots Group or Austin cars here in BC. I performed many different mods to their powertrains. Remember the ones that shared the same gearbox oil as the engine? Well, one of the mods involved removing the core of the stat which deflected more coolant flow to the back of the head damping the effect of 'head cavitation'. The increased flow helped with cooling at the sacrifice of cabin heat and later with ani-polution devices that require higher operating temps to function properly.

Would a similar crude method work better in the Bongo diesel considering that our 'Aircare' doesn't monitor or test beyond 'opacity'?

The access to the stat housing is quite good [well... after removing the exhaust manifold! ].

I have access to thousands of breaker vehicles within 5 minutes from where my shop is. I can get parts from a myriad of places here in BC. Whereas total dependancy on the UK might make owning one of these Bongos near impossible. I am afraid that if I expense too much more money on new parts from abroad, I will exceed the initial purchase price. Even more, I am concerned about breaking down and being at the mercy of our Auto Association to tow me back. Add the potential down time awaiting parts and you see where this is going.

I have faith in my workmanship and general knowledge of auto mechanics; but am I up against rebuilding the BongoBunny with 185k on the ticker?
Anyone else supporting a Bongo with higher mileage??

progroup wrote:Hey Haydyn; I like the coolant sensor mod you produce. We use an exhaust gas measurment as well, a 'pyrometer' I believe. I think one of your exampled products has the same metering option. But I am watching my budget now because of the recent expenditures totalling over half what I paid for the vehicle.

Do you or anyone else have any easily sharable specs on engine oil pressure limits, normal operating temperature, boost or vacumm mods, injector tweaks?

Nearly thirty years ago I used to specialize in Roots Group or Austin cars here in BC. I performed many different mods to their powertrains. Remember the ones that shared the same gearbox oil as the engine? Well, one of the mods involved removing the core of the stat which deflected more coolant flow to the back of the head damping the effect of 'head cavitation'. The increased flow helped with cooling at the sacrifice of cabin heat and later with ani-polution devices that require higher operating temps to function properly.

Would a similar crude method work better in the Bongo diesel considering that our 'Aircare' doesn't monitor or test beyond 'opacity'?

The access to the stat housing is quite good [well... after removing the exhaust manifold! ].

I have access to thousands of breaker vehicles within 5 minutes from where my shop is. I can get parts from a myriad of places here in BC. Whereas total dependancy on the UK might make owning one of these Bongos near impossible. I am afraid that if I expense too much more money on new parts from abroad, I will exceed the initial purchase price. Even more, I am concerned about breaking down and being at the mercy of our Auto Association to tow me back. Add the potential down time awaiting parts and you see where this is going.

I have faith in my workmanship and general knowledge of auto mechanics; but am I up against rebuilding the BongoBunny with 185k on the ticker?
Anyone else supporting a Bongo with higher mileage??

The 185k may well be (will be) kilometres. If that's the case then I'd suggest the engine safely has double that mileage within it's power.

Yes, I am fairly confident about the mileage. However, given that it was imported by the bloke I bought it from [he spent months locating this vehicle apparently], landed in BC in February, the mileage was about 165,000k. He gave it a quick service, new tires, and off on a South American [Costa Rico] round trip nearly 20,000k in my Bongo.

When I was considering buying this unit, I did a 3 hour test drive on hills etc, the Bongo was given to me for the afternoon. I also spent 4 hours under a hoist pulling all the wheels, calipers, pads, and mic'd the rotors for wear. There were absolutely no leaks anywhere EXCEPT a minor oil residue in and around underneath the Turbo unit oil return hose to block.

The under carriage I estimated to be consistant with other vehicles showing upwards to 200k given the years on the road. Thus a sixteen year old vehicle w/185k is considered on the lower side of wear/tear compared to the average 20k per year on most vehicles. These are typical BC Canada stats I refer to.

Cheers,
Dave

321Away wrote:pump/injectors are directly driven from crank and aligned with a woodruff locating key,if your taking your head off, why are you taking pump off?? the lower pulley thats in front of the pump DOESNT drive the pump, thats fixed to the same gearing and drives the cam, put the engine/cam in TDC (using 36mm socket on crank nut) and look at the crank pulley, it has a pointer, the drive pulley (fuel pump) has a marker about 10 o'clock and the cam is at 12,mark them all up and ur done.

The injectors are basic mechanical spring relief type pull 1 apart there's nothing intricate inside,still do it carefully tho!

Julian

Super, thanks Julian! No, I hadn't touched or removed the injector pump. TDC mark check okay; but w/o front visual I didn't know off hand where the cam mark needed to be. I would have thought a straight edge lining up the two marks was the method opposing each other, the cam at 7 o'clock and the crank at 1 o'clock.

I have rebuilt other injectors before, for example SD22 & 25 Nissan engines which were very popular in small trucks & boats. I believe Volvo Penta Marine engines used these also.

FYI: I ended up finding and ordering both the Diesel Service Manual & Electrical CDROM from Clup Shop. Don't know how I missed that... oh well