power loss on hills

[Doone]

no power problems, the thing goes like a rocket now...

Great news!

popped down Glastonbury on Saturday.

I know I'm completely off topic, Al showed me your 'ruin' photos, they're amazing, very atmospheric.

[berrega]

Havent finished yet.
I'm going to try and get the rest up tonight

[Doone]

We'll have a look later.

[berrega]

Mmm, well now the cold weather has gone back, the vans gone back to being dead in the mornings and needing 5 minutes to start. So unfortunately it looks like replacing the glowplug relay did didley squat.

Also since I couldn't start it last night after work also, probably suggests, it is less likely to be a 'fuel running back issue, and more likely to be an electrical issue.

The really annoying thing is that I didn't have a starting issue until I sent it away for the power loss issue to be fixed

Why did i buy a cursed Bongo?

[dandywarhol]

Have you checked, as Mizzy suggested, to see if the glow plug feed strip isn't touching earth? If the new plugs are shorter then there's a distinct possibility the feed bar is shorting and blowing the fuse

[berrega]

From what I can see there is a wire that connecst to the right hand site of the bar which presumable feeds it current.
The bar sits on top of the 4 new glow plugs (which dont look as if they have been screwed all the way in (no idea if this is an issue)

from what I can see the bar it totally straight and not warped at all and does make connection with the engine or anything else.

I also had a look to see If I could notice any changes that might have been done to fix the power loss problems. it all looks the same to me. The only thing that may look slightly different is the configurations of the small vac tubes on the bank of 4 air valves.

If it was shorting, which fuse would likely to be blown, so I can check it?

[Doone]

I've just answered another another 'poor starting' post. You've had so many issues with your Bongo, I've no idea if this will help, but I thought it was worth mentioning in case it hasn't been checked yet.

Do you know about the 30amp fusible link? If this blows, the engine will still start but it'll behave as though the glowplugs aren't working properly.
Location of the link is shown in the diagram ON THIS LINK. Worth knowing for future reference, even if yours is OK now.

[berrega]

Yeah, I read this post previously and thought it sounded like my problem.

only issue is I cant find any such fusable link on mine..

I'll put some photos up when I get home.

[Doone]

Is your Bongo the newer shape? I don't know if it's in a different place on that and hubbys not here so I can't ask... but it may look different to the one in the pic, they usually have a plastic cover, and the link's under the cover.

Also, when 'draper3000' checked his link it was OK, and he went on to find this solution:

The fuses by the drivers knee were definitely fine.


After taking on every ones advice we thought we'd solved it...

We replaced the fuse in the fusable link as it looked knackered, very very corroded and old.

Tried that but no...made me think oh bugger its the relay which is £85 to buy new.

Then double checked by running a wire in between the two bigger cables off the relay (bypassing the relay), still no current was reaching the glow plugs.

It turned out one of the fat wires bolted onto the positive terminal adaptor of the battery had broken. It was very stetchy and when cut open could see the wire had actually burnt apart. This was the black and blue wire that eventually reaches the glowplugs.

We fixed the wire, and the van fired up first time, brilliant.....

tried it again 5 minutes later and bugger it had gone wrong again.

We then Re-checked the big wire off the battery that had just been fixed, it had burnt broken.

Replaced with a new wire. Tried engine before the key was fully turned and the wire set fire instantly... proper wire with flames sitting on top of the battery....luckily with a swift blow of air it was fine.

....After much confusion it turns out that when refitting all the bits onto the new head that the glow plug rail was touching the bit of bendable tubing which loops round the injectors (I believe it is some sort of fuel overflow pipe). This was causing the glow plug rail to be earthed and taking a massive amount of current from the battery when turning over. Hence the wires burning through. It just had'nt happened straight away before because the original wire was thick enough to take a few doses of high voltage.

We have now pushed the tubing round the injectors out of the way of the glow plug and rail, refitted the wire and voila it works a treat....

[berrega]

yes, the new 'evil posessed Bongo' shape...

[Doone]

Evil possessed, but gradually being beaten back, inch by painful inch.

[berrega]

arn't these wires inside those black plastic Corrugated tubes?

I'm reluctant to go hacking apart amongst the wiring.

I'm terrified the old problem will come back, since knowone can actualy tell me what was done to fix it,
I dont know what I could do to accidentally to re-cause it

[Doone]

since knowone can actualy tell me what was done to fix it,
I dont know what I could do to accidentally to re-cause it

Good point.
But nothing ventured nothing gained... Is there anyone mechanically minded near you who can help?

Also found this info for the fusible link on the new shape Bongo:

Well as it happens the fusible link wire is very well hidden on the newer bongos and yes you've guessed it, once by-passed everything went fine... the wire but it really is concealed well on the new ones....

67-099 on lushprojects: http://www.lushprojects.com/bongopartsm ... no=.html#8

And this:

Hi it might be worth checking fuse No6 20amp under the hood,just in case you have a later spec vehicle.

[francophile1947]

Lorna, Lush Projects link doesn't work

[Doone]

It does now.
Do you know of any mechanically minded members in the Nottingham area who may be able to help Berrega?