Bongo Fury

Hi everyone,

I imported a 1996 Ford Freda from Japan to Canada and I am having issues getting it in shape for the road.

I have been having intermittent starting issues. The engine WILL turn over, but has difficulty firing the engine. Once the engine does start, it sputters and pours out a TON of white exhaust (unburnt diesel). Once the engine has been started, subsequent start ups are usually no issue. However if I leave it a long while (let it get cold) it has the same issues. Temperature has been 15 degrees celcius outside.

Here is what I have tried:

-Replaced all glow plugs
-Cleaned battery terminals and -ve grounds
-Tested and charged batteries (they are good- including leisure battery)
-Replaced the fusible link (original wire was frayed and snapped easily)
-Insulated the glow plug rail to prevent grounding on the fuel injectors
-Tested all fuses in the bonnet and by right knee under steering wheel
-Changed oil + filter
-Changed fuel filter

I am kind of at a loss. I followed missfixit70's post on how to check and repair glow plug relay viewtopic.php?t=51193

I will attach pictures of the relay, because I am not sure if all the wires are in correct position. The last photo shows the single copper thread wrapping around the plastic holder, but it is NOT making contact with anything.
Thank you in advance!
-Benjamin

https://i.imgur.com/WiVp8VJ.jpg
https://imgur.com/S5knxVQ
https://imgur.com/bnIMfcg

What voltage were you getting at the glow plug rail before you removed the relay?, it should be 11volts.

Yes that last image seems to show the wire at the end of the coil has snapped, I assume its free if you move it ? In which case you need either a new relay or unwind the coil and re do the connections which might not be possble!

Update -

I got it running again! Bought a new 12v starter relay (70 amp max) and installed it. Reinsulated the glow plug bar and bent it away from any metal (to avoid touching fuel lines etc).
Now it starts immediately. Feels good. Thanks everyone for your assistance.

-Benjamin

Well done.

Gonna be a stupid question but should the glow plug rail be negative?

Second, does anyone have a photo of the wiring connectors on the glow plug relay.
I've popped 2 fuseable link wires already.

Thanks

No it is normally at 12volts to heat the glowplugs, however they are only needed during starting and then the first few minutes until the engine is warm, the ECU controls the Glowplugs itself.