Bongo Fury

Hi all,
My Diesel 1995 Bongo starts up fine, but after 10 seconds the idle is rough and the engine stalls.
If I hand prime by pumping the top of the fuel filter it will immediately start again, or if I don't do this the starter motor will run for a long time before the engine will run.
As soon as she is warm the engine runs as it should.
Obviously a fuel supply problem only when cold? I have replaced the fuel pump seals, the mitsubishi type white valve is working, new fuel filter, cant find any leaks in the fuel lines, tried with the diesel filler cap off but still no luck tracking this fault down.
Any ideas would be most welcome.

Have you cleaned the banjo filter?

the white mitsi thing you refer to is the second stage of the warm up.(see recent thread regarding fast idle solenoids)particularly the last posts.the right hand(white)one comes in second to the left(black) one.the left one acctivates at 0--20 degrees on start up,then the (white)right hand takes it from 20 --full warmed up temps,i think the manual says about 60 ish.then off.
if yours isnt doing the first stage this may explain the poor initial starting.is it ok when its warmed up??

Many thanks, I have cleaned the banjo filter, ( was dirty) but unfortunatly this did not cure the problem. It's only on first start up it does this, once it has been running it is fine.
I know the white mitsi is working because if I plug/unplug while the engine is running it throws in a leaver next to the throttle cable. I can't tell what the other one does, so i'll investigate.

Mark Norton wrote:Many thanks, I have cleaned the banjo filter, ( was dirty) but unfortunatly this did not cure the problem. It's only on first start up it does this, once it has been running it is fine.
I know the white mitsi is working because if I plug/unplug while the engine is running it throws in a leaver next to the throttle cable. I can't tell what the other one does, so i'll investigate.

Yer white one should also work when the AC is put on too... You could (as i did) swap the connectors over briefly & see if the black comes on with the AC..? If not, the black Mitzi solenoid could be shot?? (its normally the white that goes...)

Both Mitzi solenoid were o.k. Allthough I've just boken the top off the white one, very brittle plastic these. Don't know what to try next.
Story so far, EGR blanked off, Exhaust manifold studs done, Fuel pump seals replaced, Fuel filter swapped for the later, no prime type, and swapped back again, new fuel filter, banjo filter cleaned, fuel lines checked for pin hole leaks, new air filter, glow plugs, fuel cap off.
Seems as though it starts on the button, then it's like it runs out of fuel, hand prime it and it will start on the button again, but I have to go through this 2 or 3 times if it is cold. Once it has run for 5 mins the engine runs perfectly, very quiet, no smoke.

sounds like its pointing to the pump internals.are you happy that you did the pump seals ok?.
not done the job myself,but in theory it could be internals sticking/sucking air maybe.
just chucking in some maybes

Hi Mark Norton,

It might be worthwhile checking to see if your vehicle is fitted with a non return valve in the fuel line and that it is operating correctly..

Cheers..

Mark Norton wrote:Both Mitzi solenoid were o.k. Allthough I've just boken the top off the white one, very brittle plastic these. Don't know what to try next.
Story so far, EGR blanked off, Exhaust manifold studs done, Fuel pump seals replaced, Fuel filter swapped for the later, no prime type, and swapped back again, new fuel filter, banjo filter cleaned, fuel lines checked for pin hole leaks, new air filter, glow plugs, fuel cap off.
Seems as though it starts on the button, then it's like it runs out of fuel, hand prime it and it will start on the button again, but I have to go through this 2 or 3 times if it is cold. Once it has run for 5 mins the engine runs perfectly, very quiet, no smoke.

mitzi pajeros have the solenoids(offside inner wing mounted low down above the wheel) and mazda 626 petrols with egr systems.

Many thanks for your replys, Managed to make a sleeve out of a biro pen and superglue the broken Mitz soloniod back together.
Just inspected the fuel lines etc again and can't find any fault, so i've been for a drive and put Red X Diesel Fuel line cleaner in and filled up with Diesel as i'm off to Blackpool from London Saturday, so maybe a good run will help.

Have a look at the short flexible fuel pipe that returns unused fuel to the tank, it is behind the manifold on the drivers side. I had this fault the pipe would be ok when cold but when warm leaked fuel out and air in.