Bongo Fury

Stargazer wrote:Hi Guys

Thanks for all your helpful advice, I have had to give up on it tonight due to loss of light, a dodgy back and the cold! Shall resume later in the week. The glow plugs should be the correct size as I checked the vin plate and ordered the correct size - I think - will double check though as I still have the old ones for reference. Lots of helpful advice so thanks to everyone - will let you know how things pan out and what the answer is - when I find it.

Cheers for now.

My old one was shown as having 83mm plugs, but was actually fitted with 102mm I fitted the 83mm ones anyway, but there was hardly any gap between the rail and the injector pipes - I think it may have only been the plastic around the rail that stopped them shorting out, but vibration could possibly wear the plastic insulation away. If you do find that that is the problem, send me a PM and I'll tell you what to do to fix it

I'm sure they were the correct size but I could check? The bongo had the full service a couple of weeks ago and had been driving fine up until now. before the service we had had an issue with starting (Happened a couple of times, both times the Bongo was parked on a slope?) not sure if this issue is related to whats happened now....quite likely? Hope to look at it again later

shouldnt really stop it starting,but check the fast idle solenoids thread,may give you some pointers.

Hi Guys,

Think I may have found the problem! Having double checked the glow plugs I noticed that the new ones fitted on the recent service are the 83/85mm NGK Y-701J plugs ordinarilly fitted to Bongos pre VIN 300306 - Of which our Bongo is one. However, the old plugs that came off the Bongo measure 92mm long so I guess we have one of the modified bongos of the 95-96 era. Having looked at the glow plug rail and fuel pipe arrangement with the 83mm plugs in, it certainly looks like it may well give rise to a short between the glow plug rail and fuel pipes.

So next time I get some day light I shall fit some new 83mm plugs and give them a whirl!!!

Shall let you know the outcome.

Cheers

Stargazer

Brilliant

im sure that will be the problem

If new glow plugs wont help try this simple test, you need another person to help.
- disconnect power wire from main rail - glow plugs, keep round terminal away from touching anything around
- disconnect outlet diesel pipe from diesel filter
- pull out small rubber pipe, it is returning diesel pipe between injectors and pump, it sits under inlet manifold, easy to see between
no.2 & no.3 cylinder
- get small funnel and fit to the end of diesel pipe (you pulled out from filter)
- keep the funnel above injectors level, slowly pour diesel till you see diesel coming out from metal returning pipe (injectors) &
small rubber pipe from the pump
- connect back small rubber pipe, keep funnel full
- take 2-2,5mm electric wire, connect to "+" terminal on the battery, let the helper be ready to start-crank the engine
- keep touching another end of wire to injectors rail - same place where you disconnect before
- count off 15-18sec, take off electric wire and get started
- if engine starts let fennel be empty and push pipe back to the filter
- run the engine for 2-3min, turn off, fit back all clamps, connect power wire to injectors rail and start again

Bongo wont start in few hours time or next day you have problem with sucking air in to fuel system. Check all pipes, clamps, diesel filter & housing for leak before touching the pump. If you sure your electric system for glow plugs do the test without extra power wire.
If the engine wont start this way take off timing belt cover and check marks on crankshaft, diesel pump and camshaft pulleys. Do not turn engine with camshaft bolt !!! it turns anticlockwise, turn it with crankshaft pulley bolt. Also take of top cover and inspect valves clearance - might be no right compression.
After all this job engine still wont start I guess you have to visit good workshop
Good luck

Hi Everyone.......Just a quick post to confirm that the "Glow plugs issue" was indeed the problem, changed them for correct size last weekend and Bongo now running fine!

BIG THANKS to Everyone who offered their help and support on this forum...You Guys are great