bongo won't start.. :-(

[waycar8]

, so its either 2 things, glow plug relay or the fusabkle link.


30 amp fusable link comes off the + battery terminal up behind the battery to the glow plug relay, check the 30 amp fusable link first, if thats ok then its the relay

[missfixit70]

There's a 30 amp fusible link going from the positive termnial of the battery to the glow plug relay which is on the inside of the drivers side wing behind the starter battery. Check whether the glow plug rail is getting voltage using a multimeter when the key is turned to the first position on the ignition & the glow plug light is lit, you should hear the glow plug relay click on.
It could equally be fuel not getting through, either from a blocked pick up, blocked filter or blocked banjo filter/strainer.

[westonwarrior]

If its the Fusable link you can replace this with a Fused link from bits bought from Halfords etc which will be faster than getting a propper one from a Mazda dealer

Also it it blows again you only need replace the fuse instead of the whole link,

make sure its a 30 amp fuse and the holder and wire is rated above that

[ronhud]

Are you sure you checked the fuse in the fuse bank by the driver's knee? It's listed as Engine. I had the same problem shortly after buying mine and that was the answer. It blew a few times and it seemed to coincide with starting the engine without waiting for the glow plug.

Ron

[draper3000]

ITS ALIVE AND KICKING!!!!!

Many many thanks for all the help ( and sorry for not noticing the post earlier mentioning the glow plug relay ).

The fuses by the drivers knee were definitely fine.


After taking on every ones advice we thought we'd solved it...

We replaced the fuse in the fusable link as it looked knackered, very very corroded and old.

Tried that but no...made me think oh bugger its the relay which is £85 to buy new.

Then double checked by running a wire in between the two bigger cables off the relay (bypassing the relay), still no current was reaching the glow plugs.

It turned out one of the fat wires bolted onto the positive terminal adaptor of the battery had broken. It was very stetchy and when cut open could see the wire had actually burnt apart. This was the black and blue wire that eventually reaches the glowplugs.

We fixed the wire, and the van fired up first time, brilliant.....

tried it again 5 minutes later and bugger it had gone wrong again.

We then Re-checked the big wire off the battery that had just been fixed, it had burnt broken.

Replaced with a new wire. Tried engine before the key was fully turned and the wire set fire instantly... proper wire with flames sitting on top of the battery....luckily with a swift blow of air it was fine.

....After much confusion it turns out that when refitting all the bits onto the new head that the glow plug rail was touching the bit of bendable tubing which loops round the injectors (I believe it is some sort of fuel overflow pipe). This was causing the glow plug rail to be earthed and taking a massive amount of current from the battery when turning over. Hence the wires burning through. It just had'nt happened straight away before because the original wire was thick enough to take a few doses of high voltage.

We have now pushed the tubing round the injectors out of the way of the glow plug and rail, refitted the wire and voila it works a treat....

Still other issues with power, but that's another story.

Had time after this to fit new brake pads to front and rear wheels....

Massive thanks to my Dad a true master of all trades....where as I am jack of all trades master of none.

It is now ready to go off to a garage to get the power problem sorted, (possible turbo issues) and an MOT.

Cheers to everyone

Jon

[francophile1947]

....After much confusion it turns out that when refitting all the bits onto the new head that the glow plug rail was touching the bit of bendable tubing which loops round the injectors (I believe it is some sort of fuel overflow pipe). This was causing the glow plug rail to be earthed and taking a massive amount of current from the battery when turning over. Hence the wires burning through. It just had'nt happened straight away before because the original wire was thick enough to take a few doses of high voltage.

Sounds like you replaced 102mm plugs with the 83mm ones

[draper3000]

plugs were left the same....just badly placed/bent tube round injectors I think....

[missfixit70]

Glad you got to the bottom of it

[mikeonb4c]

Just got back from a stonking Bongoing around the Lakes in some wonderful weather. Started to read this thread and wondered if anyone had considered a shorted out glowplug bar (its befuddled one or two owners before, but usually due to longer plugs being fitted). So I'm too late to offer advice (not common for me to guess it right anyway) but great news its fixed and running OK

[missfixit70]

Great minds Mike

[g@ndy]

Im having a few porblems with mine now, after I let the battery run flat, I spent a day charging it and it started okey.

However, now with the key in we are not seeing the glow plug heater symbol on the dash until we turn the key to start it. The symbol then comes on and it struggles to start but it does start.

Is this down to low battery voltage as its not getting used much these days?

Any help would be appreciated.

[munroman]

Im having a few porblems with mine now, after I let the battery run flat, I spent a day charging it and it started okey.

However, now with the key in we are not seeing the glow plug heater symbol on the dash until we turn the key to start it. The symbol then comes on and it struggles to start but it does start.

Is this down to low battery voltage as its not getting used much these days?

Any help would be appreciated.

As a first step I would be checking the battery voltage, if the battery got really flat it may be damaged, and not up to par.
Are you saying that you turn the key to the ignition position - e.g. Oil light lit, but that there is no glowplug light? The glowplug light only comes on when you are 'cranking' the engine?

Please report back so we can be clear what you mean.

[g@ndy]

Oil light lit, but that there is no glowplug light? The glowplug light only comes on when you are 'cranking' the engine?

Yes that what is happening. I dont drive the bong, however the mrs says it doesnt do it all the time. The battery was completely dead, and since then its only had a few 5-6 miles run outs. Could just need a good long blast.

I will get myself a volt meter, many thanks the reply.

Regards Andy.