A complete engine replacement and cooling system rescue
Some vans arrive with a sense of urgency. This particular Mazda Bongo, one of the later fly-by-wire models, came in after a website enquiry with suspected head gasket failure. These models are known to be far more problematic than the earlier throttle cable variants, so our team prepared for the worst.
Vehicle Recovery and Testing
We collected the van from the customer and brought it straight to the workshop for inspection. Our pressure test confirmed the suspicion — the head gasket had failed. Unfortunately, what we found next meant it would not be a simple repair.
Internal Engine Damage Found
Once we began disassembly, the true extent of the damage became clear. The cylinder head had suffered visible damage, and cylinder number 4 showed signs of serious wear. Repairs to the original engine were no longer viable. The most reliable solution was to replace it entirely.
Engine Replacement with a Reliable Low-Mileage Unit
We sourced and fitted a used low-mileage short block and cylinder head, making sure every other component was fully refreshed in the process. This included:
- New head gasket set
- New coolant temperature sensors
- Thermostat
- Rocker cover gaskets
- Timing belt kit
- Water pump
- Fresh coolant, filters and engine oil
Every part was installed with care to give this Bongo the best chance at a long and trouble-free future.
Cooling System Repaired Properly
As we refitted everything, we discovered the van had previously been fitted with a slimline aftermarket radiator. These are not suitable for Mazda Bongos and will often lead to repeat overheating. We replaced it immediately with a genuine Bongo radiator, restoring the cooling system to full capacity and giving the engine the protection it needs.
Back on the Road, Safe and Sound
With the replacement engine installed, cooling system corrected and fluids refreshed, this fly-by-wire Bongo is now running beautifully. What began as a suspected head gasket fault turned out to be a much larger issue, but with the right approach and proper parts, this van is now reliable once again.
The customer now has confidence to head off on adventures without the constant worry of overheating or breakdowns.
Think You Might Have a Head Gasket Problem?
Fly-by-wire Bongos are known for overheating issues. If yours is showing signs of trouble, like coolant loss, temperature spikes or white smoke, don’t wait. Catching problems early can save you thousands in repairs.
Need a Mazda Bongo Transformation of Your Own?
Whether you’ve got corrosion issues, cosmetic wear, or mechanical concerns, we can help bring your Bongo back to life. We’re proud to offer honest advice, expert workmanship, and results that speak for themselves.
Saltney, Chester CH4
Call us on 01244 907 079
Email: info@mazdabongoautocentre.co.uk
Visit: www.mazdabongoautocentre.co.uk