"Bongo Down" - Coolant Leak - Tue/Wed 16th/17th December 2014

Top Radiator Hose
Leak

Have Tools
Have Knowledge
Have Confidence - Check!
(Good Hand)!

After a very enjoyable day at College on Monday, assisting Julian Jones with Workshop 3 pre-standown preparations, and undertaking tasks such as checking tool trolley's and providing pin-outs' on the resident Volvo S40, all was going swimmingly!  Off to work I went, did my shift and then headed off to Asda for a resupply of moo-juice.  I arrived in the car park accompanied by a big "hiss", and clouds of steam emanating from under the bonnet - not the best entrance I have ever made!  I was unable to determine the precise location of the problem at the time, due to poor light visibility, however my shopping list rapidly grew to include 5 litres of still water in order to get me home!  

With nothing brighter than a wind-up torch and a fading will to stay awake, I duly sent an e-mail to Carl Roberts to notify him that I would not be in College the following day.  My priority had to remain with finding an alternative means of getting to work the following day, and with further investigation in daylight, sourcing the replacement parts first and foremost.  I remained confident throughout, not only because I now had suitable tools again, but also the knowledge and confidence to be able to tackle the fault regardless!

Tuesday 16th December 2014

Hose sliced for ease
of removal

Draining Radiator from Bottom Hose
and Flushing with Fresh Water

In the clear light of "First Thing" Tuesday morning, and having removed the top air intake ducting, the fault became apparent after a few squeezes of the various likely hoses.  I was straight on the blower to my Bongo specialist in Surrey - "Top radiator hose please - fast as you can"! (Genuine replacement part, Next Day Before 1 pm - £32 incl postage), I was happy with that - especially considering I'm off to Norfolk for the bi-annual "Davey Migration" next week!  In the knowledge of the part not arriving until the following day, I then proceeded to make as much progress in advance as possible.  

COSHH Zone

I drained the radiator into a suitable container, by disconnecting the bottom hose, and then flushed the radiator through with fresh water to get as many deposits and residues out as possible. 


With the radiator drained and the bottom hose reconnected, I then set off on foot with a 5 litre container to AA Automotive Services in Pentre, in order to try and obtain some assistance in obtaining some antifreeze.  Andy Kirby is an absolute "diamond" of a fella! - not only did he "gift" me 5 litres of the Pink Stuff, but he also gave me a lift back home in a 2.7 litre Mercedes he was about to test drive - which didn't take long at all (thank you so "very" much again Andy)!  With as much done as possible it was then on the phone to the Deeside Shuttle to arrange transport into work later that evening - lift home also priorly sorted.


Wednesday 17th December 2014

Coolant System
Bleeder Hose
Mazda Bongo/Ford Freda

Ha Ha!
Call that a Funnel?!
Hot Hot Hot!

The replacement hose arrived at 1230 hrs and I was already prepared and kitted up for the job at hand. The Bongo Coolant System contains 13 Litres (which is a lot), and I made up a 10 Litre 50/50 mix in a bucket accordingly (which transpired to be "just enough").  The method of bleeding out the air in a Bongo Coolant system is "unique", and I attach a YouTube video below to more fully explain.  The Mazda Bongo/Ford Freda, is fitted with an additional coolant "bleeding hose" (usually sealed at the far end) and situated beneath the passenger seat, and is connected at the other end to the top of the engine block on the nearside.  The process is described (both on the video and also within the "Official" Workshop Manual), as "Sea-Sawing" (You will have to view to fully understand)!  Not an easy operation to undertake on your own, but thankfully I had my lodger on hand to assist with monitoring header tank levels, whilst I "Sea-Sawed" and operated the throttle to get the system up to operating temperature, and the thermostat to subsequently function accordingly!! (Incidentally - anyone who introduces themselves as "Master Bongo" (Video Part 1 Omitted for embarrassment reasons) needs to be treated with extreme caution)!  Clearly the funnel I had to hand to undertake the operation was "minute" by comparison - and yes - it was hot work, but as Steve Leonard aptly says - "approach Storeman and respectfully request a Can of Man-Up"!

Thank you to "all" who have provided me with the confidence and skills to undertake such operations, and to "all" who have provided me with the resources and kindred support of the above endeavors thereof!!  Merry Christmas One and All!!