Fuel system... need some advice please.

[onilleymcknown]

Hi everyone,

My Bongo (4X4 2.5 Diesel, 1999 new shape) has been going well until recently. Now it just won't start up. It's turning over fine, but won't come to life. I've spent the last 2 weeks researching this forum, replacing things, and then trying to start the engine. Everything is unsuccessful. So here's what I've done so far.

- New air filter
- New oil and filter
- New glow plugs
- New fuel filter just last week.
- Tested glow plugs to ensure they're receiving electrical current and heating up. All fine.

Still not coming to life, except for the occasional grunt, but I think this is residual fuel in the lines. Still turning over fine. Have been keeping the battery charged externally.

So, after reading more, I tried to see if fuel was getting to the injectors successfully. I unbolted some of the fuel pipes and turned the starter to see if any diesel shot out. Nothing. Also tried pushing accelerator too. Nothing.

Went back down the fuel pipes and unbolted at the fuel pump. Tried again. Still no fuel.

Went further down and undid the white cap on bottom of fuel filter. No diesel there.

Took the fuel filter off again, there's no diesel in it.

It appears there's no diesel in any of the fuel lines. When I press the accelerator I can hear a faint electrical 'buzz' sound, coming from the area around the rearmost cylinder. It goes off when I release the accelerator.

Do all these clues mean that my fuel pump is not working?
Guess I can't really bleed the injectors of air if the fuel pump doesn't work?
How can I tell if the fuel pump is operating?

Thank you for any replies. Photos below. 1st is new fuel filter. 2nd is fuel pipes coming out of fuel pump and follow up to injectors. 3rd is a whole engine view.

onilleymcknown

[missfixit70]

Assuming there's sufficient fuel in the tank ( got to ask in case fuel gauge is faulty ) , check the banjo filter on top of the fuel pump & check the pump operation by sucking from a known clean source of fuel with a known clear pipe, ie a bit of tubing & a jerry can of clean diesel. That'll elliminate possibilities.
It could be the tank pick up, blocked or damaged.
This thread - http://www.igmaynard.co.uk/bongo/forum/ ... 75#p274375 - may be of some help.

[onilleymcknown]

Ok,

Will give that a try. Thank you for your advice.

onilleymcknown

[scanner]

One thing you could try to check out that scenario is disconnect the supply pipe from the tank to the filter housing and blow down it and see if it's clear.

If you can hear bubbling then it's clear.

If that works, get a length of clear hose that will fit tightly into the supply pipe and try sucking up diesel until it appears in the clear tube - if it does (good idea to stop sucking then) then the supply pipe is unlikely to be the problem.

[Bongopatrol]

Hey onilleymcknown
Where abouts in Belfast are you I live just outside Ballyclare and I am also a mechanic so should be able help if your interested.
Let me know cheers Gary

[The Great Pretender]

Assuming there's sufficient fuel in the tank ( got to ask in case fuel gauge is faulty ) , check the banjo filter on top of the fuel pump & check the pump operation by sucking from a known clean source of fuel with a known clear pipe, ie a bit of tubing & a jerry can of clean diesel. That'll elliminate possibilities.
It could be the tank pick up, blocked or damaged.
This thread - http://www.igmaynard.co.uk/bongo/forum/ ... 75#p274375 - may be of some help.

I love the lets start from basic logic.

Get a bottle (not Guinness a clear 1) and some fuel pipe. Remove the feed to the injector pump and connect the pipe, insert pipe into bottle after you have filled the bottle with diesel, Try to start engine, if it works air lock or blockage, if it dosn't, pump problem.

[onilleymcknown]

Ok, no blockage from filter to fuel tank. I have to run up and get a spot of diesel for the pump test.

Gary, thank you. Nice to know someone familiar with bongo's is nearby.

onilleymcknown

[Bongopatrol]

onilleymcknown if you look at the second picture down you will see just above the fuel pipes screwed into the pump is the stop solenoid you need to check you have a 12 volt supply going to it if you do then screw the solenoid out of the pump and remove the little spring and plunger and screw it back in then minus them then loosen off the injector pipes and crank the engine over to see if you get fuel through this may take a minute or two if you say the filter is dry the other you could do is fill the filter with fuel before you start to crank.
Hope this helps cheers Gary

[mikeonb4c]

onilleymcknown if you look at the second picture down you will see just above the fuel pipes screwed into the pump is the stop solenoid you need to check you have a 12 volt supply going to it if you do then screw the solenoid out of the pump and remove the little spring and plunger and screw it back in then minus them then loosen of the injector pipes and crank the engine over to see if you get fuel through this may take a minute or two if you say the filter is dry the other you could do is fill the filter with fuel before you start to crank.
Hope this helps cheers Gary

Tell you what onilleymcknown, how lucky are you having Bongopatrol nearby to offer support. Well done indeed BP

[onilleymcknown]

I know. You are right! This is great, especially because right now I'm broke!!

Just spent £400 on brakes all round, a new tyre, and a full coolant flush!!

Now maybe a fuel pump? Think I'm suckin' a lemon here?

Anyways, you guys are the best!

Thank you so much! I'm gonna try the solenoid now.

onilleymcknown

[onilleymcknown]

Just did the bottle test. Pump is not drawing fuel up the transparent piece of tubing i'm using. So, Gary, are you saying that perhaps the pump isn't getting power? Will check.

onilleymcknown

[bigdaddycain]

Is the filter full of diesel?

[onilleymcknown]

no, bdc

i have a bottle of diesel with a clear pipe connected direct. Takes the filter out of the equation.

i have just removed the solenoid. tried starting it without the spring and plunger Gary said to take out. The pump sucked the diesel out of the bottle, but not at a very powerful rate. It sort of went up the tube and then came back down again. I don't know what all of this means.

In order to get to the solenoid, I had to remove the top set of fuel injector pipes. So while they were out, I blew through them. No blockages there.

Gary, Ravenhill Road.

picture below.

onilleymcknown.

[Bongopatrol]

onilleymcknown that looks like a broken wire on the picture with the solenoid is that the way it was or did you break the wire when you removed it by the way I dont know who does you work but £400 seems pretty steep.
If you want to pm me your mobile number I will give you a shout to see if I can help.
Cheers Gary

[onilleymcknown]

Hi Gary,

The wire is fine. It's connected by an insulated connector. Maybe indicates there was a problem with the previous owner.

ok will pm you.

onilleymcknown