How To Change Coolant On 2011 Ford Escape 2.5

_{All advice is given in good faith and believed to be correct just is followed at you own risk..}

_{Factsheets are at the bottom of this page.}

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You name it, I can probably do information technology!

24hr driblet off and collection can exist arranged.

Since 2003, I've worked on Bongos every weekday and many weekends. I've shared a lot of advice on the Bongo Fury forum and Facebook groups. This page has many of the questions I've been asked most frequently.

The Mazda Bongo was also produced as the Ford Freda. The trim differs but they are mechanically identical.

They're a versatile 8 seat MPV, suitable for everyday apply. They're congenital to the usual high Japanese specification.

The Bongo has 2 body types; The AFT (auto gratuitous meridian) or tin-superlative (flat roof). The AFT roof raises; this gives standing room in the Bongo. Information technology also forms a roof tent, with sleeping infinite for two adults. The tin-top roof does not raise.

In all models, the seats fold down into a double bed. When used every bit a Camper, adding a side or tailgate awning tin can double the living infinite.

The rear seat layout differs betwixt earlier and subsequently models. All models have 2 rows of seats backside the commuter and passenger. Each row holds 3 people, with two 3-point seatbelts and a centre lap chugalug. The seats are adjustable and they slide. On before models, the rear 'gullwing' seats flip down/fold abroad. This allows enough of kick space when non used for passengers. In later models, this is a bench seat which does not fold away.

All seat backs fold apartment. Some have picnic tables incorporated into the dorsum of the seat. Flip-down step seats can be added backside the commuter and rider. These flip-down, so 2 people can sit at the picnic tables.

The ii.five diesel Bongo is sold as a 4-wheel drive (SGL5 model numbers) and ii-wheel drive (SGL3 model numbers). Its turbo engine has enough of power.  Its torque converter locks betwixt twoscore-45mph, giving good pulling power.

All petrol model Bongos are two wheel drives. The 2.5 V6 Bongo is a placidity engine and is noticeably more powerful than the petrol 2l Bongo.

Here are Mazda Bongo engine specifications, so you can compare performance figures:

Mazda Bongo engine specification:
2 five diesel:
Engine Power kW 88 kW/120 HP
Torque 310/2000 Northward*g/rpm
2.v V6 petrol:
Engine Power 117 kW/160 HP
Torque 211/3500 N*m/rpm
2.0 petrol:
Engine Power 77 kW/105 HP
Torque 162/4000 N*m/rpm

The fuel consumption of all engines averages at 26mpg. This depends on use; constant stop-get-go around boondocks tin reduce that figure. Steady driving and a calorie-free foot on the throttle tin can increase it to 32mpg.

Almost Mazda Bongos have four speed automatic transmissions. The 5 speed manual gearbox is rare.

Mazda Bongos are approximately 4.vi metres long and i.7 metres broad. The elevating roof model is 2.1 metres high; the tin-peak is ii.0 metres.

Many Bongos are converted to camper vans. These are either dealer converted or DIY self-conversions. There are many different side and rear conversion layouts and the specification varies. Others are 'weekend' campers with removable kitchen pods that are interchangeable with the rear seats.

Spare parts and accessories, both new and used, are available for the Bongo.

Mazda Bongo and Ford Freda have a cult following, Facebook pages, clubs and forums.

If you're buying a Bongo then it'due south adept to go one with a decent Service History. So you lot know if it'due south been properly looked after. If y'all're looking at i that been previously owned in the Britain, it should accept service history.

Plenty of people exercise their ain servicing and should have receipts for the parts they've bought. If information technology's been serviced by a garage, there'll be invoices and receipts.

If y'all're looking at a newly imported Bongo, service history is rare. Just you lot can ask to see the 'auction sheet'. This shows the full general condition of the Bongo when it was sold at sale in Japan.

For more than information on the auction sheet, read this page on our website.

If you have the registration number, you lot can check the MOT history online. You lot tin check the mileage recorded at each MOT. Sometimes when a vehicle passes an MOT, there is withal work that is 'brash' to be done. These are generally things that are OK for now, simply will need doing adequately soon. Y'all can check if there are whatever 'advisories' and inquire if this work has been done. Here's the MOT history link: https://www.gov.u.k./check-mot-history

It's sensible to accept a adept look around the Bongo, inside and out.

Prepare to get your knees grubby! Get downwardly on the basis and look underneath for prove or leaks or corrosion. Common corrosion areas are the front end and rear crossmembers, inside the cycle arches and inner and outer cills. If it is corroded, many can be welded and repaired, so you can cistron the toll of repair into the purchase toll.

If a Bongo has been undersealed, it will take a black or clear coating over the metal. This tin can be waxy and slightly gluey or await similar thick pigment, depending on what the Bongo was undersealed with. A few Bongos are just undersealed on the very edge of the underbody, so wait further than the edge. If it'southward not undersealed, you'll meet bare metal.

Sit within the Bongo and check all the controls work - aircon, forepart and rear heating (when fitted) or climate command, all wipers, windscreen and rear screen wash etc. If information technology's non obvious, enquire what the switches are for. If the Bongo has rear heating and air conditioning, go far the back and make sure it works via the controls on the side pocket.Bongos need a rear fog light to pass the UK MOT. Check that ane has been fitted - it's surprises me to still encounter Bongos with an MOT but no rear fog lite.

Check that the AFT roof rises smoothly and fully; there should be no creaking noise from roof struts or bagginess in the sides of the roof tent canvas. It should beep when raising and stop beeping when fully open up, unless the beeps have been disabled. Look at the outside of the roof tent to check it's fully raised and non amorphous or straining. Look inside the roof tent to cheque for mildew or impairment to the tent, net screens or zips.

Bank check the spare wheel and tyre. The standard one is a 'space saver', designed to get you to a place of repair. They often still have the crumbling, original Japanese tyre. You may wish to cistron in the cost of replacing this with a standard size cycle and tyre, which will fit in the same storage space.) . The wheel is  stored beneath the "boot" of the Bongo. It's lowered with a bar, that'due south stored in the cubby hole in the side door step. (Sometimes the bar is missing. A replacement tin be pricey so factor the price in, if it'south not in that location.) Lower the spare wheel to cheque it.

Y'all probably know that a Bongo engine is under the commuter and rider seats. At that place are more than components under the bonnet. While the engine is common cold, l ift the bonnet to inspect the header (overflow, expansion) tank. It's commonly discoloured so you won't come across much from exterior. Remove the cap and look in; information technology's useful to have a torch for this, even in daylight. Ensure there are no copper coloured particles or gloopy sediment. If you see any, it tin can propose a 'leak stopping' additive has been used, so ask the seller for reassurance. Leak stopper or K-Seal is sometimes used to conceal a cylinder head problem. Check the brake fluid and windscreen wash while you're there.

Ask what antifreeze the owner uses, as you'll need to utilise the same type. Nigh now utilize standard UK blueish or carmine antifreeze. Just don't mix the two types. Once bought, you may similar to flush the system, as sediment can build up in the radiator and atomic number 82 to overheating. Ask when the thermostat was last changed. If information technology hasn't been washed recently, yous should change it. A glutinous thermostat tin can cause the cooling system to overheat.

Take information technology on a long road examination, incorporating hills. Check the temperature guess when driving uphill. The standard gauge should never ascension above the '11 o'clock' position. It's 'dumbed down' by Mazda and will only rise to a higher place that when it has a cooling problem. If another temperature gauge is fitted, the Bongo runs at most 82* as standard and a bit more on hills.

Pull away on a slope; The Bongo should pull abroad smoothly without bike hop or juddering. When driving, the engine should accelerate well and gear changes should exist smooth. The steering should be light, not heavy or notchy. Braking should besides be smooth, with no judder from discs or vibration from the pedal.Likewise bulldoze it in reverse to ensure there are no problems. Check the tyres are wearing evenly across the tread and there are no cracks in the side walls.

While test driving, heed for knock or clunk noise when going over bumps. This can suggest steering or suspension problems.

Lift the seats to check the condition of the cooling organisation hoses. These are rarely changed until they neglect; many accept been on the Bongo for10+ years. If they fail, the system can rapidly loose coolant and overheat. If a hose (or metal pipe) has a deadening leak, coolant loss can become un-noticed, until the system overheats. Look for swelling or cracking on the hoses. Check for rust stains on pipes, hoses the engine block, cylinder caput - anywhere where water could squirt or drip from a leak. If y'all notice whatever, ask what caused it and run into proof that it'southward been stock-still. There should exist an invoice for work done by a garage, or a receipt for parts if it'southward a DIY repair.

There are a couple of common oil leaks on the Bongo. Yous may meet a very small oil leak backside the diesel fuel pump and an oil weep around the rocker encompass gasket.  They leak slightly for years and aren't an immediate problem unless the leaks are bad. Wipe them away; it'll exist obvious when the leak is bad because you'll need to wipe more often, the engine oil level will drop more apace and you may observe an oil fume odor. On the V6 petrol Bongo, the rocker embrace oil leak can eventually seep into the sparkplug holes; if this happens, the engine volition misfire. On the 2 litre Bongo, the oil leak from the rocker cover somewhen finds its way onto the gearbox and manifold; you may notice the smell of oil fumes if this has happened.

There should be no diesel leak from the diesel pump.

Bank check the engine oil and gearbox fluid (ATF) levels and atmospheric condition. A check of these might reveal either emulsified (creamy) engine oil or chocolate-brown ATF (gearbox fluid). Emulsified oil suggests an engine trouble. Chocolate-brown ATF that smells burnt suggests a transmission problem.

I've mentioned 'overheating'. This is said to be a common trouble with Bongos. It's non. But it is a common problem with Bongos that haven't been properly maintained! One-time parts, pipes, hoses, oils and fluids don't last forever. So double check the service history! If things have been omitted, factor in the cost of getting this rectified.

You'll detect more advice on buying a Bongo, on the various Facebook groups and Bongo websites. This link is the Mazda Bongo Facebook group I ready in 2008: https://www.facebook.com/groups/7571714956/

I've put together a comprehensive Mazda Bongo buying guide. It has more information. You can download it, from the list at the lesser of this page.

I tin carry out an inspection of your Bongo, if yous bring it to me in Plymouth. Click on this link for more than advice on Bongo Inspections.

My own Mazda Bongo custom choice-up and 2.5d Bongos in Plymouth, Devon.

HOW I MADE THE PICK-UP.

In 2006, I had a inexpensive black Bongo as a billow, for spare trunk parts. Mechanically, it needed a lot of work. The body was the all-time function of.

So I had an idea that information technology might look pretty good as a pick up. Something to build in my spare time. It took me over ii years... And then much for spare time!

At that place was a lot of measuring, word, cutting and welding. In one case the dorsum was off the Bongo, it was also light, so I added weight.

I strengthened the chassis and body.

I rebuilt the cantankerous member and replaced the rear quarter panels.

Getting the Bongo tailgate to open was tricky, but I got there.

I cut down the Bongo's AFT roof as a 'chapeau' for the cabin.

I blanked off the Bongo's rear air conditioning and heater pipes equally I'd removed half the system when I'd chopped the dorsum.

I rebuilt the Bongo 2.v diesel engine.

I carried out a major service and replaced coolant hoses and pipes, radiator and water pump.

I fitted four new shock absorbers, suspension bushes and links.

I fitted new restriction discs and pads all circular.

I replaced the Bongo'due south transmission and all it'south rusted oil pipes.

(I told y'all it was in bad mechanical condition.)

The weight of the Bongo, every bit a option upwards, was radically different to the MPV it had originally been, despite increasing the chopped trunk weight. Then I tried a few different wheel and tyre combinations until I was happy with the way it handled. Getting it tested was nail biting, but all was OK.

 I had the Bongo pick upwardly'south body resprayed black, with a subtle metalflake laquer.

The Bongo's seats were refinished in leather by Paul at Wixenford.

I stained the mats and carpets blackness (see details below).

I added a different steering wheel, a pod of gauges, new temperature judge and white dials. I had a graphite style dash from another Bongo I was breaking, so I fitted that. I'm nonetheless adding to the option-upward, in my spare time...

If y'all're passing and would similar to see my Mazda Bongo pick up, pop in. It's been SORN'd, waiting for work and a new MOT... when I detect the time!

Allans Mazda Bongo pick upwards.

I get asked dozens of questions almost Bongos. Some simply need a curt respond, others are complicated and can take hours to reply to! I demand to put my customers showtime, so unfortunately don't have time to answer all questions. In that location are also several Bongo forums and groups. This is my Facebook Mazda Bongo Group.

HOW TO CHECK BONGO COOLANT LEVEL

The Bongo de-gassing tanks is ordinarily called the expansion or overflow tank. They're usually discoloured, and so the coolant level is hard to see. A new tank is available direct from a Mazda main dealer and (at the time of writing) costs virtually £100!

Unless the tank was leaking, I'd go along my money in my pocket, and work out how to check the level on the discoloured tank.

The level should exist checked regularly, to monitor for coolant loss. Only open the expansion tank when the engine is cold. If you open up information technology when the engine's hot, the coolant may spray out and could burn you.

I dip my finger in to check the level. If my finger tip touches coolant, I know the level'southward OK. With a fleck of practice you'll become the hang of just how far to reach.

Or use a stick (coffee stirrer), marked 2cms from the stop - come across the motion-picture show. Dip the stick in until it touches the lesser of the tank. If it's moisture on the the 2cms line, at that place'southward enough coolant in the arrangement. Information technology shouldn't be above or below this level.

If a pinnacle-up is needed, pour the correct coolant into the tank. If you overfill, some of the coolant will come out of the pigsty y'all're filling through.

The cooling system on the Bongo is pressurised. If you put in as well much coolant, the excess will exist expelled nether pressure, when the engine is hot. If this happens, re-check the coolant level when the engine is cold.

If the Bongo engine overheats, the valve on the coolant tank cap opens. It releases pressure and coolant. When this happens, owners sometimes mention hearing a 'rumbling racket, then a hiss'. This is the coolant boiling in the tank, so hissing on hot metal, equally information technology is expelled.

Do non change the tank for one from a dissimilar vehicle! The design of this 'de-gassing' tank is an of import part of the cooling system. It allows expansion of the coolant, which raises force per unit area to allow greater heat transfer to occur. It likewise releases absorbed gasses into the space in the tank, above the coolant.

I can check the cooling system on your Bongo,  flush the cooling organization, supersede whatever parts, fit alarms and kits. I have bled hundreds of Bongo cooling systems over the last xviii years.

EMAIL LINK

In that location'southward e'er a reason why a Bongo overheats. This fourth dimension, it was due to a faulty coolant temperature sensor. The temperature sensor monitors the temperature of the engine coolant. At a certain temperature, it volition actuate the cooling fans. If information technology doesn't, the Bongo will run hotter than it should. It will also use more fuel. The one I had in this time had overheated. It'southward now back on the road, running perfectly.

This one had an air lock, preventing coolant circulation. It had lost 5 litres of coolant and the temperature gauge had risen. Information technology was topped upwards, but the air wasn't bled from the system. When driven, the temperature judge rose over again. The coolant loss had immune a lot of air to enter the arrangement. It prevented apportionment of the coolant.

Luckily, the cylinder head didn't fissure. I was able to skim it and refit with new head gasket, head bolts and coolant. I replaced the leaking piping and hoses that caused the coolant loss.

If a garage or recovery service tells you it'south OK to drive a 2.5d or V6, after losing a lot of coolant, it'southward sensible to ignore that advice.

This Bongo overheated because the thermostat was chock-full with silicone sealant.

At a certain temperature, the thermostat opens. This allows coolant to circulate fully and cool the engine properly. Considering it was clogged, information technology couldn't open and the engine overheated.

There's no reason to utilise silicone on a thermostat.

A thermostat will terminal for many years, nobody can predict when it volition fail. I e'er change a thermostat when replacing cylnder heads or doing major work on the cooling organisation. If yours hasn't been changed for several years, it's sensible to change it.

SWOLLEN COOLANT HOSE

This coolant hose is sometime, worn out and ready to burst. Luckily I spotted it in time, during a routine service & MOT.

As you lot can see, the surface of the hose looks OK, except that it'due south swollen.

There's no firm rule on how long a hose will last. I've seen them neglect after v-x years, depending on the mileage of the Bongo. Some last longer; they've been lucky. Check hoses regularly, become used to what they feel like, so you tin recognise when they're failing.

Hoses wear from the inside out, and then the vesture is rarely obvious. As they age, the rubber tin become very thin and you will sometimes see blisters on the outside. On this one, the wear is pregnant and a large portion of the hose has swollen but non cracked or blistered.

When cold, hoses should feel house, not difficult, spongy, or soft. Check for pinholes, surface cracks or abrasion. You may see weeping coolant around clips or stains left by leaks.

It's important to know that coolant hoses can neglect without obvious alert, so be enlightened of how old yours are.

If you're irresolute them yourself, I recommend yous always fit good quality replacement hoses. You lot can buy 18-carat hoses from a Mazda principal dealer. I don't fit silicone hoses as the quality is too variable. Hoses are held in identify by compression or jubilee clips. Clips tin lose compression, so may need to be changed at the same fourth dimension.

This Bongo Coolant Hose Guide can exist downloaded as a factsheet from the links at the bottom of this page.

Modify THE COOLANT HOSE

Customers have often asked me to "change all the hoses". I'm happy to do this. Merely in that location are a lot of hoses and changing them all at the same time, is not always affordable. And some may already accept been changed, before you owned the Bongo.

If you don't want them all changed, it is sensible to change the ones that neglect well-nigh ofttimes. I tin likewise just modify just the hose that has failed and advise on the  condition of the others.

There are also metal pipes in the cooling system. These will rust and leak. They should too exist changed equally required.

Low coolant alarms are bachelor for the Bongo, which tin can warn of slow coolant leaks. They are unlikely to relieve an engine from sudden hose failure, when a lot of coolant is rapidly lost.

There are seperate pipes and hoses that cool the gearbox and should also be maintained.

Go in touch, if you lot'd like me to change your Bongo coolant hoses or pipes.

COOLING Arrangement DIAGRAMS

In 2011, Steve Widdowson produced animated diagrams of the Mazda Bongo cooling system. It took him ii enthusiastic years, from his initial query, to producing the animations!

He was assisted past many of u.s.a. enthusiasts, behind the scenes. Temperature sensors were fitted at various key locations and the data exchanged betwixt us, with many interesting debates.

The temperatures earlier and after the thermostat opens, the change of the coolant flow and the heater circuit, are clearly shown in his diagrams. Hither's a link to them on Bongo Fury.

Approximate dimensions

ROOF TENT DIMENSIONS

The AFT (Auto Gratis Top) Mazda Bongo has a raising roof, with a roof tent. This provides a sleeping expanse for 2 adults.

There are 3 different sizes of roof tents. The difference is hard to discover without measuring. The early on model Bongo upwards to 1999/2000, has the lowest peak roof tent (see epitome). The 1999/2000 onwards (shape change) model has the highest roof tent. And the tent of latest model Bongo is betwixt the two sizes.

If repalcing the tent, be sure to order the correct size. My guide to removing the roof tent is below and can be downloaded every bit a factsheet from the bottom of the page.

HOW TO Raise THE ROOF

The roof tent is the raising roof of the Auto Gratuitous Summit model. Luckily they abbreviated this to AFT model! It's commonly known as the pop-top Bongo. Here are the nigh common reasons why the roof tent can fail to open. They're all problems that are piece of cake to fix, DIY. This information is all included in the 'AFT pop-tiptop' downloadable Factsheet, at the bottom of this page.

To raise the roof: Use the handbrake, the handbrake light illuminates. Press the roof button that's located on the roof, between the driver and passenger seats. It will bleep every bit it rises.

To lower the roof:There's a double hatch to enter the roof tent. It's sensible to close the large part, earlier lowering the roof. I find information technology helps to forestall the fabric from snagging. Press the 'unlock' push that's on the light in the roof. And so press the roof push. It will cease halfway down, then you can cheque there are no obstructions left in the roof. Press the button over again, to total lower it.

ROOF SEAL IS STUCK

The rubber seal which surrounds the roof provides a seal between it and the body of the Bongo. When the roof is rarely raised, the seal can stick to the body. Although eveything else is working, the roof won't heighten. Simply run an former banking concern card (or similar) between the seal and the body. This will free information technology upwardly. You lot tin employ a seal lubricant, like that used on a sunroof, to proceed it in good condition.

ROOF SWITCH WON'T Work

If you press the roof switch and it doesn't blip and the roof doesn't rise, check the handbrake light is on. If it is, and so the roof switch could be stuck. It can stick from lack of use and because dust and crud build upward inside information technology.

Flick the roof switch several times, to try to free it up. If this doesn't work, you tin remove the switch to clean it.

The well-nigh difficult bit is getting the switch out. It's held in by a rocker tab on each end. Push the body of the switch forward, insert a modest screwdriver at one terminate, nether the roof lining and backside the tab. Lever it, the switch will come free.

In one case you have it in your hand, press the ii ends and the black switch will popular out of its gray moulding. You then carefully divide the switch itself, by pressing the end tabs and levering. Remove grit and clean with electrical contact cleaner, not WD40. If y'all search on YouTube for 'vehicle switch cleaning Bongo' you'll find a video that clearly explains the procedure.

If you press the roof switch and it does bleep merely the roof doesn't rise, the motors could exist stuck or have failed.

HANDBRAKE SWITCH Lite

The roof won't rise if the handbrake isn't applied.

If the handbrake is on, check that the handbrake light is illuminated on the dash. This low-cal completes the electrical circuit; the roof won't operate if it'southward not lit.

If the lite isn't lit, lift the eye consul. Yous'll encounter the handbrake switch. Information technology has a small spring and a white clip, fastened to a cable. The switch can get clogged with grit. Remove the dust. Wiggle the switch a few times, the low-cal should illuminate and the roof will operate.

All the AFT information can all exist downloaded in a Factsheet at the bottom of the page.

ROOF TENT MESH REPAIR

The insect mesh (mosquito cyberspace) in the Bongo roof tent, keeps insects out and provides ventilation.

Equally it ages, the textile degrades and information technology can tear.

The holes and rips can be repaired almost invisibly, using clear Tenacious Tape. This is ordinarily used to repair sails. It'south available from gunkhole chandlers or online.

The mesh can as well exist replaced. Some Bongo owners have managed this, without removing the roof tent. It takes patience! Replacement mosquito internet is avaialble online. Measure, cut out the old net, sew in the new.

HOW TO REMOVE THE ROOF TENT

The AFT roof tent can be removed to undertake larger repairs. Ii people are needed to move the tent to the ground.

The tools required are: JIS (Japanese) screwdrivers or Phillips screwdrivers sizes P3 and P2. A drill, 3/viii Ratchet, A correct-angled screwdriver, araldite glue or popular rivets.

Full instructions on removing the roof tent are in the downloadable Factsheet, at the bottom of this page.

MOULD IN THE ROOF TENT

Mould spreads in warm, damp conditions. Condensation within the roof tent is perfect for it!

To minimise it, increase ventilation by leaving the roof flaps open. Open up windows or doors if cooking in the Bongo. If you're sleeping in it, exit a window ajar at nighttime, if safe to do so.

If the roof tent is airtight while wet, dry it out equally soon as possible. When not in utilize, notwithstanding raise the roof on warm days and open zips, to dry and air the tent. While information technology'due south airtight, Bongo owners take institute that containers of wet absorbing granules, inverse regularly, can help.

If mould is nowadays, it tin be treated. Bongo owners have institute success with various products. These incluse clove oil, white vinegar and lemon juice in water and various mould and mildew removers. If using chemicals, they can degrade fabric. try to notice one that's prophylactic on textile. Rinse whatsoever chemical cleaners afterward application and allow to dry  thoruoghly.

CHARGE AND SEDIMENT LIGHTS ILLUMINATED

Bongo alternator:

If the Bongo charge light and the sediment light illuminate at the same time, it means that in that location is a fault with the alternator. It should be refurbished or replaced.

Ensure the new alternator is rated at xc amps. Some are but fourscore amps and so may neglect sooner than expected.

REMOVE AND REPLACE SPEEDO FACE

How to remove the speedo face up

Disengage the four screws that hold the black cover in front of the speedo. Pull the cover off. Undo the iv screws that hold the instrument cluster. Lift out the cluster. Disconnect the two or 3 mulit-plugs from the back. Remove the blackness panel that agree the drinking glass (push clips). If you don't have the proper tool, employ 2 metallic spoons to lift the needle from the speedo confront. Y'all use the basin of the spoons on the needle and press on the handles. (It'due south easier than it sounds.) Undo the 2 screws that hold the speedo face up on. Lift it off. Fit the new face.

How to zero the needle on a new speedo confront

Fit the speedo unit of measurement (without the glass) back into the nuance, with all wires connected into the back of it.

Don't fit the needle-stop post to the speedo confront all the same.

Switch the ignition on. Fit the needle in the zero position.

At present fit the stop-post and drinking glass.

Bongo cylinder head

Buying, Plumbing equipment BONGO CYLINDER HEAD

I helped write a similar post for the Bongo Fury forum. I've added more detail hither, equally several people struggle to fit a Bongo cylinder caput. Or they detect the cooling system won't bleed after they've fitted a new cylinder head.

This communication is for general guidance only, to brand you aware of some of the checks that may be needed.

When a new cylinder head is supplied every bit 'fully assembled' or 'ready to fit', do not assume that it is fix to fit. Information technology'due south advisable to bank check it first.

Once unpacked, cheque for hidden packaging debris inside the head.
The caput confront should be clean and free from grease.

And information technology should be smooth, free from scratches, nicks or damage. If it's not, you'll have to return information technology or fix it. Otherwise it volition leak and lose compression. Yous'll struggle to bleed it.

A smoothen surface is needed so that it will seal.

To ensure a tight seal, check the deck of the head and cake.  This YouTube link is to a 'How To' video. It shows you how to deck a block DIY, without specialist tools.

Information technology'due south possible that valves and collets volition already be fitted. Only you lot should check to ensure the collets take been fitted correctly.
Check cam caps are tight.
Check all fitted items are tightened to the correct torque, including the rocker caps.
Check valve and tappet clearances.
Check the camshaft oil seal is in place.
Fit injector heat shields.
Ensure the oil gallery plug is tight.
Ensure the dowel pin is fitted correctly and is perfectly aligned.
If the head is supplied with a seal kit, you may not need all the seals - cheque with the supplier.

Bongo water elbow

Heads are sometimes supplied with a ii piping water elbow. This is not standard on the Bongo and you lot'll struggle to drain it. Purchase a iii pipe water elbow. The Mazda part number is: WL02-10-2EO.   The elbow is  tight to remove or fit. To remove, twist using a wrench. To fit, I add thread sealant to the elbow. The big pipe (of the elbow) faces front end of Bongo. Tap it into identify with a wood mallet. (You could use a cake of wood and hammer if no mallet.)

Some parts are tin exist transferred from the quondam head. This will relieve you lot money.
Simply I recommend plumbing fixtures some new parts:

New caput bolts; Erstwhile bolts usually stretch and won't tighten fully once again. If this happens, the head won't seal.

New exhaust manifold studs; These harden with age and can snap when removing or re-tightening. Number one manifold stud, nearest the alternator, is peculiarly prone to snap, possibly to the varying temperature it receives. If you lot don't replace all the studs, play safety and have a couple to hand, in case they're needed.

A new fan sensor; This is specially important if the previous caput has overheated, equally excessive oestrus can damage the switch and the fan won't operate when information technology should.

A new thermostat; The thermostat helps to regulate the temperature in the cooling organisation. If it'southward faulty, the temperature of the coolant volition exist affected. If the coolant gets too hot, your Bongo could overheat again. The comparatively small cost of a new thermostat is definitely worth paying.

Nosotros tin can supply and fit a Mazda Bongo cylinder caput for you lot.

Merely we don't supply the cylinder head for y'all to fit yourself.

This data can likewise be downloaded as 'HOW TO GUIDE', run across below.

When irresolute the Mazda Bongo V6 cambelt, I  besides modify the guide wheels, tensioner bearing and hydraulic tensioner.

I recommend replacing the camshaft and crankshaft seals at the same time. The seals don't add a huge amount to the parts cost.

The failed seals leak  oil onto the cambelt and damage it. The cambelt will fail.

The oil as well drips downwards the drivers side, onto the tiptop of the alternator. This can eventually damage the alternator.

Replacing the seals at a different time, means changing the cambelt again. The same labour price, all over again. In the long run, you'll save a lot of money by having them replaced at the same fourth dimension as the cambelt.

It's advisable to as well change the water pump, if information technology hasn't been washed recently. This is considering a lot of the same labour is involved if changing information technology seperately.

A flashing hold light doesn't always mean a gearbox problem.

It sometimes flashes after it's been raining heavily. It seems to be related to the connections on the side of the gearbox. Spray them with WD40. To clear the fault code, disconnect the positive concluding in the battery. Put your pes on the restriction to fully discharge. Reconnect. See if it notwithstanding flashes.

Is your speedo 'chipped'? Chips tin become faulty as they age. That can make the concur low-cal flash. Alter the fleck or remove it and fit an after-market speedo confront that shows MPH.

The plug-in wiring behind the speedo could be loose. Behind the speedo face, there's a screw on the printed circuit. It'south marked as 'sp out'.  Basically it sends the signal to the ECU.
The screw works loose. So the signal fails. Tighten or replace the screw to ready it.

It's rare, but possible for the connection to the agree button itself to become loose. It's nether the centre delegate and runs through a connector.

But if the Bongo hold light is flashing and it's driving abnormally, information technology could mean a speed sensor or gearbox trouble.

If the speed sensor has failed, the flash will probably be quite slow. Information technology will probably exist staying on and off for the aforementioned length of time.

If yous need to read the gearbox fault codes, y'all tin can spark them out yourself. Use i piece of wire to connect the pins on the ECU. The hold light itself will flash out the codes.

Or utilise an analogue multimeter. The long and short flashes will be indicated by the needle movement.

More information on how to read Mazda Bongo fault codes has been shared by Phil McFadden on THIS LINK

EGR systems are added to standard Bongo engines, to run into the strict Japanese emissions limits.

If the Bongo EGR arrangement is working equally it should, there'due south no need to do anything to information technology.

When the Bongo EGR fails, information technology ordinarily jams in the 'open up' position. Signs of a faulty EGR system on a Bongo can be a combination of loss of ability, black smoke, knocking noise, excessive fuel consumption, smell of oil fumes in the vehicle.

The pipes of the EGR organization can leak; the manifold or turbo will lose back-pressure. Yous will detect a lack of ability from the engine and may smell fumes, which tin cause nausea and headaches. This can all be fixed!

As blanking the EGR is no longer legal and is checked during MOT, I no longer sell the blanking plates. The best option is to spend a fewhours removing the EGR, cleaning it and checking for leaking pipes.

While working on the Bongo EGR, you may notice a green one-way valve. This is plastic, it becomes brittle and can break. It affects the common cold-start function. If the valve is cleaved, information technology can be replaced. Y'all tin can either lodge a replacement valve, currently only from a Mazda primary dealer. Or you can fit a (much cheaper) ane-way windscreen washer-pump valve! These are available from most motor factors. I used one several years agone on my own Bongo and information technology yet works fine!

When you put the EGR dorsum, exist careful to reconnect vacuum pipes, or the EGR can remain diconnected, assuasive exhaust fumes to circulate into the inlet manifold, causing a 'dirty burn' and using excess fuel.

I'm stating the obvious, simply if you fit a used EGR organisation, make clean it before fitting.

Hither'due south a handy Wiki link with general info on how to clean an EGR system. It's not a Bongo EGR but is still useful advice: CLICK ON THIS LINK.

I can clean or modify your Bongo EGR arrangement. Get in touch on to book.

Nearside NS mounting point

If you lot have a tow bar on your Mazda Bongo or Ford Freda, check it.

The Mazda Bongo was non designed as a tow vehicle. There are two 'mounting points' for a tow bar. They're on the drivers side (OS) and passenger side (NS) rear. The NS mounting point is only spot-welded. This means it's likewise weak to hold a tow bar and it's load; information technology will be stressed and may neglect. This mounting point needs to exist strengthened, before plumbing fixtures a tow bar.

The OS mounting point is fixed to the chassis and is stronger, provided the chassis is solid and not corroded with rust.

If a tow bar is already mounted to the NS mounting point, the mountain will need to be strengthened. You may find a drooping rear bumper! The bumper can be removed for admission before welding. It'south not always necessary to remove the tow bar, only it tin can too be removed if needed.

The Bongo and Freda are susceptible to corrosion (rusting) of the rear cantankerous member. The crossmember contributes to the force of the chassis. Any tow bar attached to a weakened chassis is at hazard. A corroded rear crossmember should be removed and a new one welded into place. It will terminal longer if it is besides undersealed.

There are now a couple of different styles of tow bars for a Mazda Bongo; they're mounted in different ways. TowTrust have altered the design of their Mazda Bongo tow bar and it at present mounts to the chassis. A1 also manufacture a tow bar that includes mounts on the chassis. Please let me know if there are other tow confined for the Mazda Bongo, that mount to the chassis, and I will add them.

I tin can cheque your tow bar mounting point and acquit out whatsoever welding or repairs you lot need. Please get in bear on to arrange this.

Please go far touch if you would similar to book your Bongo or Freda in to take the mounting points checked, crossmember replaced, welding or undersealing.

AIR Conditioning

Why isn't the air conditioning working?

The about common reason is because the air con gas needs topping up. To foreclose damage, the system will automatically shut downwardly when the gas is besides low.

The air con system naturally loses some gas over time. It generally needs topping up every ane – 2 years, depending on use.

When I re-gas (elevation upwards) the air con, I also add the correct corporeality of PAG oil. This is vital as information technology lubricates the system and helps to continue the seals supple, so they don't leak.

When seals dry out, they leak and the gas will escape. So run the air con all year round, for at to the lowest degree a few minutes each week, to help to proceed the seals in proficient condition.

Please be enlightened that some of the newer models have less gas, probably due to a change in the pipework. Don't overfill the system and monitor when filling.

The guideline figures nosotros take are:

Front aircon only: 700gm gas + 14ml PAG.

Front end and rear aircon: 950gm gas + 14ml PAG.

Year 2000 onwards: 750gm gas + 50 PAG.

Nosotros can drain, check for leaks, repair and re-fill Mazda Bongo aircon systems. Delight go far touch to book this.

Middle seat on a Bongo

REVERSING THE Heart SEATS

Turning the seat to face the rear, gives you more space in the middle of the van. Under current MOT rules, rear facing seats do not need seat belts.

I've reversed Bongo seats many times. Information technology's a straight forwards job. The seat is heavy. Turning it in a confined space is much easier with 2 people. The residue you tin manage solitary.

The only tools you need are a Phillips screwdriver, a 17ml socket and ratchet, and a hammer.

To save me writing the instructions up over again, delight run into the photos and advice given by dvisor on this link.

Carpet dye

DYING THE BONGO CARPETS

Several years ago I dyed the carpets in my Bongo pick up.

They were a well-worn faded grey. Afterwards dying they almost looked new! They nevertheless wait good after several years.

I used Autosmart 'midnight black' rug dye. Information technology'due south used by valeters and often availabe from them. It'due south also sold on EBay and Amazon. I estimate you need about v litres to dye all the carpets in a Bongo

Spray bottle

I decanted the dye into a cheap paw-held spray canteen  I sprayed a sparse coat, allowed it to dry and applied another coat. It took about 5 coats to achieve the depth of colour I wanted.

The dye smells when moisture, so spray in a well ventilated area; you might want to wear a mask. Information technology stains anything it blows onto, and then wear gloves and move anything you don't want sprayed!

Throttle pedal 'terminate'

BLACK BUTTON IN THE FOOTWELL

I'm frequently asked what the black push button under the Bongo throttle pedal is for. Despite the rumours, I'k deplorable to say, it doesn't operate an ejector seat or take yous dorsum to the future.

It's simply a 'cease' for the throttle pedal. It stops the pedal being pushed any further.

If you remove it, there are no hidden controls. You'll just find the fixings that hold information technology (and the rug) in identify.

CLEANING HEADLIGHT LENS

The headlight lens on a Bongo is made of polycarbonate plastic (PCB). UV rays from sunlight degrade the outer layer, causing information technology to look irksome. The light of the headlight bulb cannot shine clearly through the cloudy lens and visibility is reduced.

Some headlights are also coated in a yellow fim, which suffers from in the same way.

Luckily it's fairly simple to restore clarity to the lens. We've found a skillful video from AMMO NYC that shows three different methods of doing this yourself.

Hither'southward the link: RESTORE FOGGY HEADLIGHT LENS.

Or become in affect if you'd similar me to do this for you.

UNDERSEAL A BONGO, DIY

I've been waxoyl undersealing Bongo for over 17 years. Despite being a time consuming, mucky job, some people adopt to do their own undersealing.

I recommend wearing overalls, gloves and eye protection. The fumes are waxy and you don't really want to breathe them in, then also wear a protective mask.

Protect the ground under the Bongo with a dustsheet or tarpaulin as waxoyl is very hard to remove!

I found a video that shows you the nuts on Waxoyl undersealing.

Here's the video link: HOW TO WAXOYL UNDERSEAL A VEHICLE.

I've been undersealing Bongos for over 17 years and in that time, I've establish information technology's an effective mode to assist to dull down or prevent corrosion.

Click for details on my Bongo undersealing service in Plymouth, Devon.

The advice given is believed to exist correct but followed at your own risk.

The guides are listed in alphabetical guild.

If you're unsure how to fix your Bongo, please go in touch on to volume your Bongo in with me.

AFT pop-top roof won't raise or lower
Bongo roof non working, roof stuck, uncomplicated fix for common trouble
AFT roof won't operate.docx
Microsoft Word document [42.0 KB]

ATF Automatic Transmission Fluid cheque
How to check the ATF level (gearbox oil level)
ATF Check.pdf
Adobe Acrobat document [178.seven KB]

Buying a Bongo guide
Our comprehensive guide to buying a Bongo, with information from Allan's site.
Bongo Buyers Guide.docx
Microsoft Word document [32.7 KB]

Ownership a Bongo guide
Our comprehensive guide to buying a Mazda Bongo, with information from Allan's site.
Bongo Buyers Guide.pdf
Adobe Acrobat document [506.iii KB]

Rear facing childs car seat
Bongo auto seat, Grouping 1-2, 9-25kg, rear facing car seat.
RearFacingCarSeat.pdf
Adobe Acrobat document [107.8 KB]

Roof tent, AFT performance
Bongo AFT roof won't open up? What to check. How to open and close the roof tent.
Bongo Roof tent operation.docx
Microsoft Word document [202.5 KB]

Join MY MAZDA BONGO FACEBOOK GROUP!

 I created a Mazda Bongo Facebook grouping, over 12 years ago. You can conversation, enquire questions, mail service photos, arrange meets, buy, sell & swop Bongo stuff!

CLICK HERE TO GO TO MY FACEBOOK GROUP!

Allans Vehicle Services,

Wixenford Depot, Plymstock, Plymouth, Devon, PL9 8AA.

VAT no: 909 7647 fourscore

Source: https://www.allansvehicleservices.co.uk/bongo-service-inspect-underseal/mazda-bongo-tips/

Posted by: kintzelsishomistend.blogspot.com

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