Loss of power (safe mode?) - Problem with fuel pump sensor?

[dangam10]

Have been searching round the forums and various places that you have suggested but can't really find a definitive answer so I thought I'd get in touch for a bit of bongo expertise!



I have a 2002 2.5TD 4WD Bongo Aero Tin Top



Today, driving to work the glow plug light came on and the vehicle's power dramtically dropped. I have since learnt that this is the safe mode. I took it to a friend of mine who put it on a 'launch' diagnostic check which came up with the error: P1189 - Fuel pump speed sensor/wiring. He turned off the trouble code but when I started driving it came on again after fives minutes. Interestingly when I stop the vehicle and leave it for a bit the light turns off and it's alright to drive...for about five minutes again!



I took my van to a Japanese parts dealer to get a replacement sensor. I explained the problem and he looked at the Fuel Pump and said that because it was a newer model of Bongo he didn't think much could be done to fix the pump (change sensor etc...) and that I would need a complete new pump which obviously would be at a great cost.



On the recommendation of a friend (also a bongo owner) I took it to a couple of Auto Electricians and explained the problem and showed them the diagnostic print out. Both of them suggested that they would need to run their own diagnostic as they thought the 'launch' system was unreliable. If it showed the same fault they would then test the pump, and test the sensor and then the connection from the sensor to the ECU and then look at fixing it. One also referred me to a company that specializes in fuel injection.



I'm not sure if any of them have had any experience with Bongos before and my head is a bit frazzled with all the mechanical talk. All I can see for myself is that I've been told different things and it all seems a bit speculative and looks like it could cost a lot of money. Is it true that I would have to replace the whole fuel pump? Could it be that what has actually gone wrong is somewhat simpler and cheaper to fix?



I was just after a bit of advise with what avenue to take. Maybe you have seen Bongo's with similar problems. Don't really want to rush into it and end up having to pay hundreds if I didn't really need to.



Many Thanks in advance,



Dan

[dandywarhol]

Unlikely to be a complete pump failure IMO Your pump does have replaceable sensors

http://www.lushprojects.com/bongopartsm ... mgno=.html

[dangam10]

Thanks for that, much appreciated! Just to be sure, it's a newer model 2002 Aero Bongo. Would be great if I didn't have to fork out for a whole pump!

[dandywarhol]

The diagram is for a 2001 onwards engine

[bigdaddycain]

Is the "heat" light working ok? (i.e. it illuminates briefly when the ignition is switched on?) Personally i'd get your nearest local Mazda dealer to run a diagnostics check on it. My own experience when this was done on a bongo of similar vintage with a similar fault, the MAZDA diag showed 2-3 sensor input faults, whereas a generic diagnostics by an independent showed up only one fault. In the long run the Mazda diag proved to be correct.

[DemonAV]

Hi. Do not buy new pump. Tested yours. May be you need replace only FIP rotary sensor.
Service code P1189 is FIP rotary sensor signal system
Detection condition: During engine turning when the NE signal from the FIP rotary sensor normally it is not input to PCM
Fail safe: Detecting engine rpm with the crankshaft position sensor
The cause of being thought:
1)Breakdown of FIP rotary sensor
2)Harness between FIP rotary sensor B terminal - PCM 2D terminals, broken wire of connector, short circuit
3)Harness between FIP rotary sensor A terminal - PCM 2K terminals, broken wire of connector, short circuit
PCM terminal(Visual direction: the harness):

FIP rotary sensor harness(Visual direction: the terminal):

FIP rotary sensor have namber 531 on this pic http://www.demonav.ru/For_work/104700-0530.PNG All Bosch/Zixel numbers for this pic here: http://mikrob.ru/download/file.php?id=1 ... 4e5d2e745e
About FIP rotary sensor: http://www.demonav.ru/For_work/F3-35.jpg

Good lack!

[321Away]

have seen similar symptoms on a late model, was made better by replacing the tacho pick up on the pump but was only fully cured by a pump replacement, was sent off for a rebuild, at @ £700 mark, a replacement is £4,000!!!
Julian

[mikeonb4c]

have seen similar symptoms on a late model, was made better by replacing the tacho pick up on the pump but was only fully cured by a pump replacement, was sent off for a rebuild, at @ £700 mark, a replacement is £4,000!!!
Julian

Ye gods! Think I'll buy a 1950s Massey Ferguson tractor and drive that as being cheaper and more reliable

[dangam10]

I've been away at work for the last week or so and haven't been able to get to a computer to post any replies. I would like to say thanks to those who took the time to post some advice. It has helped immensely and I've got my Bongo booked in tomorrow, armed with a printout from the forum page, so fingers crossed it'll be ok!! Really impressed with how everybody looks out for each other on here!!

Cheers

Dan

[dangam10]

After two weeks of not really knowing what is going on, thanks to the advice I have received on here I have managed to find out what is wrong with my van. The problem now lies with finding the part that I need, which is not proving to be very easy

I am trying to find a sensor that fits on this zexel pump(no. 104700-0530 ) (Bosch no. 9460613453) The part number is 479765-6320 (Bosch no. 9443611796). The sensor is called a FIP rotary sensor (or pulse generator).
Hope somebody can help!!

Thanks
Dan

[dandywarhol]

Are you sure thats the bosch number?

[dangam10]

My mistake! Yeah the Bosch part number for the sensor is: 9 443 611 796. The Zexel no is 479765-6320. Cheers!!

[dangam10]

Just an update. Through a tel number given to me by somebody on the forum I managed to source my sensor. The part code and sensor I was looking for doesn't really exist in the UK but they have done lots of work on my particular pump and knew that a different, virtually identical sensor did the same job. It cost me £48 and simply screws in the side. Feels like I've got a new van!! V.v.v.v.happy!! The firm was "Merlin Diesel" in Preston. They were incredibly helpful and knowledgable and anybody with similar problems would be well advised to go straight to them. Big thanks to all those who have helped along the van, in particular DemonAV.

Dan

[DemonAV]

Good news.
Do you know identical sensor number? Or from which pump?

[dangam10]

I'll try to find out. I know it's made by zexel. I'll get back to you.