Bongo Model and head gasket/service parts

[MaxBasher]

Few easy questions I hope... Firstly I have a 2001 2.5TD 4WD Bongo, is this the SGL5 model? Are parts for the 4wd 2.5TD generally the same whatever the year? (I've seen the glow plugs vary though)

Secondly - got my Bongo going in for a bit of work, full service and having the head gasket seal replaced as it's got a leak from the oil way Doesn't seem essential to do but the burning oil smell while driving it a tad annoying!

Having never bought anything for the Bongo before though, was just after some reassurance that I was ordering the right stuff and from the best place - couldn't find some of these things on here so ended up on AVA leisure, anyone know if they are ok? They certainly seemed to have the most idiot friendly descriptions and everything I think I need (at good prices):


Mazda Bongo Set of 3 filters - Diesel:
Filter set 2.5 turbo diesel. ***FREE DELIVERY***
Price Ex VAT: £24.96
Price Inc VAT: £29.95

Mazda Bongo Head Gasket set:
set fits 2.5 turbo diesel engine 1995 onwards
Price Ex VAT: £79.96
Price Inc VAT: £95.95

Mazda Bongo Head Bolt Set:
Fits 2.5 turbo diesel engine 1995 onwards
Price Ex VAT: £25.79
Price Inc VAT: £30.95


And I had a free health check done by a local garage (not the guys I got lined up to do the head) and they reported that:
- Front brake pads have about 1000 miles
- Front brake discs are heavily corroded on inner edges
- Both front anti roll bar drop links rubber boots are perished
- Clip missing on nearside front steering rack
- Exhaust system heavily corroded

However they only quoted to do the front discs and pads, so should I assume I don't need to worry about the rest or they can't be arsed to buy the bits and do it? I am assuming they have gone OTT with what's wrong in order to get some work on the car

Thanks in advance for your advice

Cheers
Dan

[Simon Jones]

You should replace the cambelt, idler pulley and tensioner spring as well. I think this typically costs about £60. Cambelts should never be re-used once the tension has been removed as they will be weaker when re-tensioned.

Many of the parts are compatible within the diesel model range, but after about 1999/2000 the injection pump changed to a 'drive by wire' system and I believe the turbo was changed to a more efficient unit.

Are you 100% sure it's oil leaking from the head gasket? It's very common to get black goo around the gasket, but often this is leaking from the inlet manifold / EGR pipe work. Worth having a read up on here and double checking the diagnosis before splashing the cash on the head gasket.

[MaxBasher]

Hi Simon and thanks for the speedy reply. I get what you're saying about the cam belt, shame though as they only did it when I got the motor back in Jan this year, in fact given the lack of interest the garage has shown since I drive it away, I wouldn't be surprised if it wasn't their mechanics that damaged the seal when they did it
Would I be crazy not to get this done though?

Not 100% sure it's the oil well but had 3 garages look at it, admittedly it was the first time 2 of them had ever seen a Bongo before so it didn't fill me with confidence but the 3rd guys are old friends/ acquaintances and specialise in 4wd and import motors (although still didn't have that much experience with a Bongo)

However I do have pics (I took them after you asked last time but never got round to posting after I saw the garages, apologies it was most rude of me!)

Hopefully they make sense to you, I've ringed where I can see the oil coming from, at the moment I spray this about once a week with brake cleaner to clean the oil off but we're planning a 5 hour drive to Cornwall in 2 weeks time and I wanted to get this sorted before then.

[Simon Jones]

I remember your earlier post now . A quick search for 'oil AND leak' brings up this thread (with other links from it):

http://www.igmaynard.co.uk/bongo/forum/ ... ak#p541519

Your photos do look very similar to the problems other members have experienced and there seem to be several suggestions for causes and solutions, so I'm not sure which is necessarily the right solution in your instance.

Is your intended garage fully conversed in the foibles of the coolant bleeding process? If they know their stuff, then they are probably giving you a reasonable diagnosis and perhaps they can offer you an assurance that all the hard work and expense is going to result in a successful outcome.

Just one word of caution: are they happy for you to supply the parts for them to fit? There have been a couple of instances where problems have arisen and then it gets a bit tricky with the parts supplier blaming the mechanic for not fitting the items correctly.

[MaxBasher]

Thanks for the link, some good info from there.

I'm slightly confused as to where the rocker cover gasket sits? Is it between the light grey and black parts in the middle of the circle in my picture?

Or to put it another way, 10-235 in this image: http://lushprojects.com/bongopartsmk2/c ... o=.html#10

The oil is def. coming from here though as I've cleaned it off a few times now and seen it comes back in the same place, if this is the rocker cover gasket, that could be handy as it's a lot cheaper to buy than the whole head gasket kit! I guess it's still worth getting new bolts though to ensure it all goes back together properly?

Re getting the parts, yeah they are cool with at, it was them that suggested, I'd have rather let them buy the parts so I didn't get it wrong but saves money this way

[Simon Jones]

The rocker cover gasket is part 10-235 identifed on the diagram. You can see where it is on your photo: just below the metal (EGR) pipe that runs on top of the inlet manifold. In your case, it looks very clean around the rocker gasket and I would have expected to see black marks down the side of the head where the injectors are if the leak was coming form there or the rocker cover mounting bolts.

Perhaps one of the engine experts on the forum such as Ady (Northern Bongolow) could give you their thoughts on it .

[Driver+Passengers]

For some parts, it's probably a reasonable cost/benefit trade-off to source and supply your own. If (and I say if) you end up needing to replace the head gasket - they may say they're fine with you supplying the part(s) but in the event that there is a problem down the line, you will stand a better chance of a zero-conflict resolution if you just let them take ownership of the lot from the off.

I agree with Simon that the area below the rocker cover gasket appears to be rather clean in your photo. Just as an example - a new rocker cover gasket is what might be considered to be a "low risk" part for you to source/supply (not that there would be much difference in cost in you doing so, I don't think). In contrast, unless you're confident of the cause, the parts and your garage, I'd argue that the head gasket would fall into the "higher risk" category and you should consider the options carefully, if it comes to that.

Just a thought, while I'm sitting here drinking my coffee.

[teenmal]

Hi,

It might be a good idea to check the injector pipe conections for drips(leaks).



Cheers.

[Northern Bongolow]

thanks for the big build up there simon, but i aint no expert.
my bongo has this same leak, and has had it for the entire time ive had it (2 years). it uses about a half pint a year, so to me not worth diving in.
having pulled most bits off mine a few times my thoughts would be front cam seal, i think it will be leaking behind the timing gear plastic protector then running down the head front face unseen and round the side, but until i do my belt i wont know for sure.

maybe a phone call to alan's at plymouth will steer you right.

[MaxBasher]

Thanks for all the replies guys, I've taken the plunge and just decide to replace everything

Called Vaughn and AVA Leisure to place my order and got to say, what a nice bloke! He may have just been just been making me feel better about splashing my cash but said it was a problem he'd heard of before and thought it wise to sort now and not risk head gasket going because of it - as I say he was probably just making me feel good!

So it's all booked in for next week, gonna get a full service done on it as well just so I know where I'm starting out with it. The mechanics did the same thing to my import Hilux Surf 5 years ago and that was the best motor I every had (until I got the Bongo hopefully). Vaughn did mention that bleeding the cooling system on the Bongo was quite a skill, does anyone know off hand if there's a good guide to this (sorry bit rushed at work to search at mo)

We got our first baby due in November so figure I'll be totally strapped for cash after then, hence doing this all now

[Tony C]

Heres the link for bleeding the cooling system, good luck.

http://www.youtube.com/watch?v=jRAKOSxgbKo

Cheers Tony.