Bongo Fury

Hi Folks,
I wonder if someone could help me please.
5 years of having the bongo and I’ve never had a problem starting it - until today!

I’ve been swapping the front part of the exhaust, removing the cold start valve whilst I was there (in exchange for the straight through pipe). Started fine after fitting and I left it running to dry the exhaust paste. Turned the bongo off whilst clearing the tools away and when I went to start it to drive home, the glow plug light flashed on for a brief second, I got a very strange noise almost like a low pitch buzz / grind and the engine will not turn over and no glow plug light at all.

I’ve searched the forum and I can’t see anyone with the same symptoms.

I was thinking either glow plug relay or main relay but wondered why it wouldn’t turn over either. Also am I right in thinking if the starter motor was on its way out, I’d still get the glow plug light on as normal?

Also I’ve checked I’d not damaged the two earth straps near the exhaust – they’re both fine, I’ve check the battery and its fully charged.

For info I have a 96, 4WD 2.5 Diesel

Cheers in advance for any help!

http://lushprojects.com/bongopartsmk2/c ... no=.html#8.

click on the link above and check the main 100amp fuse, then part number 67-099, this is the fusible link at the positive batt terminal, if you have blown the 100 amp you will get no start, if the fusible link has burnt out (its like a thick wire fuse) you will have no glow plugs.

what did you do with the wiring that went to the solenoid that operated the cold start valve in the old exhaust. ??. if this is now incomplete the ecu may see a fault and put on the glow plug light, this says the ecu is possibly seeing a fault in the wiring.

Thanks for the info I'll take a look at the 100am fuse tomorrow .
I disconnected the wiring and removed the solenoid (from under the passengers seat) a few weeks ago when fitting my eberspacher D2. As far as I can remember I just tied the connector up out of the way.

im a great believer in leaving the solenoid connected to the wiring, so the ecu doesnt see a fault in the system, as its still doing its thing. others have not had any problems removing the gumins, but im not sure its the best thing to do.

Hello Again,

Just a bit of an update, the100amp fuse seems to be okay and its the glow plug relay thats making the strange noise, so I've just ordered one and I'll let you know how I get on.

Just for info I noticed the speedo flicking up and down too whilst the relay was making its strange noises!

Cheers
Nick

I wonder if you have a partial short on the Glow plug bus bar ? Its quite easy to knock the bus bar that connects all the glow plugs together and make it touch the chassis of the engine, this would then be drawing a LARGE current - but possibly not enough to blow the fuse - and cause the battery voltage to drop hence causing the problems you report.

Good point Geoff - thanks! I'll take a a look.

Cheers
Nick

have a look at 18-831 and 19-444 on the link below. failing that it could possibly be the speedo chip if fitted.

http://lushprojects.com/bongopartsmk2/c ... o=.html#10

Hi Guys, thanks for all the help so far but still I have problems...

Popped the new glow plug relay on the car and still we have the same problems.
Bench tested both glow plug relays and they're working fine (probably I should have done this with the first one before ordering the second - but 'hey ho'

11.1 volts at the glow plug rail, but with no glow plug light on the dash (is 11.1v normal?) seems a little low to me.

Tested loaded circuit (Blue/black wire and Red/Black wire) of glow plug relay, all seems to be fine.

If I remove the Blue and Black wire which takes power down to the glow plug rail. The glow plug light comes on and off at the dash (as if there is a fault). And the starter motor almost pips in but doesn't.

100am fuse removed and tested for resistance and its fine.

Under engine earth straps checked again


Resistor removed, tested (Slight resistance), earth point cleaned and reconnected - no difference.

So as per your guidance, I'll check the inhibitor - if I can find the thing.
Speedo chip - I guess it has one fitted as the dash works in MPH.
And I may refurb/replace started motor or perhaps short it to see if its working first!
Reconnect cold start solenoid

And I'll keep you updated.
Oh yes, no main relay fitted in the centre of the engine it’s never had one in my ownership - I'm not sure if this is normal??

Cheer everyone,

Nick

If you are getting a 'chattering' noise, it could be a sign of battery problems. Do all the lights on the dash dim as you try to start it? Sometimes this can be combined with the engine fan coming on briefly. Another option is the solenoid contacts in the starter motor have packed up which quite common. Possibly a gentle tap with rubber hammer on the starter casing may shock it back to life. Replacement contacts fairly easy to get & fit.

put your battery on charge or jump start it

Yes I'm getting the chattering affect and the engine fan is flicking on for a brief second but the battery is 2 months old and tested it today again and its more than healthy.

I think I may have found the issue, bench testing the starter motor the little starter gear pops out but doesn't spin, I think the starter motor has given up the ghost. If this is the problem I can't beleive the symptoms it gives

I'll report back shortly - and cheers for the continued help!

I also have the heavy duty starter motor so I'm guessing a replcement part is on the cards rather than refurbing the contacts!

Someone on here did manage to repair the heavy duty starter contacts so it is do-able.

and im sure he got it of the same guy does the regular one on ebay

http://www.ebay.co.uk/itm/MAZDA-BONGO-2 ... 1070wt_932

its worth a pm