Whats this wiring?

[Northern Bongolow]

the clear windscreen washer pipe that someone has put into the vac pipe system (see picture) also wont last 5 mins either it will suck flat when it gets warm.

you mentioned other problems you were having, what are they. is it cold starting revs etc.

[stuc]

the clear windscreen washer pipe that someone has put into the vac pipe system (see picture) also wont last 5 mins either it will suck flat when it gets warm.

you mentioned other problems you were having, what are they. is it cold starting revs etc.

Only starting problems, just splutters a bit then fires up with a cloud of smoke, which clears straight away. Runs great when started. Getting a bit worse, usually starts second time. I think I need the longer glow plugs, are these the least common? Did you see my other glow plug thread Ady, as the bit sticking out above the thread seems about 50mm. Someone has used Suzuki Plugs fitted about 5 year ago according to the history.

[jaylee]

the clear windscreen washer pipe that someone has put into the vac pipe system (see picture) also wont last 5 mins either it will suck flat when it gets warm.

have to agree with Ady.. The clear hose is for low water pressure not suction... & that pipe is right next to the engine...

Would it be better blanked/capped off after the cold start solenoids......? Ady?

I got a gut feeling something don't look right about the placement of those clear hoses in your pics Stuc...???!!!!

http://lushprojects.com/bongopartsmk2/c ... 1of02.html

Need a little more detail in the pics.....

[Northern Bongolow]

looking at the picture with the clear pipe in place they have jumped from the exhaust side of the starter solenoids to god knows where. but if the egr solenoids are removed/bypassed then the exhaust should go to the thick black air pipe via the little green one way valve. this exhausts the vac when the cold start is not needed, without this it can run with the vac still present and run on (choke).

stuc take a good picture or 2 of your glow plug (no1) and the bussbar to it, and the injector link pipe under them, we will see if we can tell which plugs you need

[stuc]

Thanks guys, but worried now even though it works fine. Will take some more pics when it is light and see what we come up with.

[stuc]

Heres some more pics, it appears the EGR valve has been blanked off. The clear pipe was not connected but looks like it should be connected to the plastic thing where the wire had come off, when running it does have a small vacuum. The other plastic thing? also has a clear pipe attached to it but not connected to anything else(picture 2). Have these things also been took out of the system?

[stuc]

I dont think my scavanger fans work but not sure how to check them,

Scavenger fan the one in front of the engine you mean??

Scav fan sensor is by the handbrake... If you unplug the connector with the engine running the scav fan kicks in?? With the engine off if you short the connections or run to ground the scav turns on too... Plug the connection back, tun the ignition on & off & the fan will stop & sort of reset....?!! Or run a hairdryer over the sensor beneath the "saddle" & it should come on??

Right! next problem, scavenger fan does not work by disconnecting, but does work by shorting it out.
So fans are ok.
Sensor seems to be ok as I put a meter across the sensor to check resistance as I put the end of the sensor in warm water. The resistance went down which indicates sensor is working. But at what point does the sensor tell the fans to switch on.
Is the sensor easy to get hold of and roughly how much?
Or am I better just connecting the fans to a switch so I can control when I want them. This may stop engine bay getting to hot before the fans kick in. I think some people have already done this.

[Northern Bongolow]

the plugs you have fitted at the moment are long plugs, or as they are not mazda ones they are equal to long plugs, so you will have to fit new mazda long glowplugs or modify short ones by extending the top threaded bar by 10mm using old spark plug top threaded bar and the old fashioned screw top off the plug as a joining nut.

the vac system looks really butchered about, do the cold start solenoids work at all????, it doesnt look from here that they can.
the vac pipe should come up from the behind the rear of the pump in steel to the bottom edge of the rocker cover half way along, then it goes to rubber and into a double T that feeds firstly the white plugged solenoid then the one next to it with the black plug. this feeds when the solenoids are triggered via the ecu the cold cold start up to about 10deg c then half off cold start/ aircon solenoid up to about 50 deg c (unless the aircon is on), it does this via the throttle diaphram mounted low down on the inj pump.
this 50 deg c is also when the egr should open via the other pair of solenoids so the vac is then used to open this via the diaphram in the bottom of the egr valve.
when the vac is not needed its allowed to pass into the air inlet pipe at the rear of the head via the little green coloured thimble one way valve.
hope this helps a bit.

the scavenger fan has an earth fault, so its ok when you earth it out.

[stuc]

HI Ady, that is great info but you lost me at the vac system. I know that the clear tube does come from the rear of the pump then it just goes nowhere. What will it be doing without any of this connected. I have had it 2 year now no cold start probs until this glow plug problem. It runs great, maybe a bit heavy on fuel but that may be my right foot.
I know from the history it has had a head gasket on about 5 year ago. Whoever done this has not put various clips and bits back on, turbo shield for example.

[jaylee]

I dont think my scavanger fans work but not sure how to check them,

Scavenger fan the one in front of the engine you mean??

Scav fan sensor is by the handbrake... If you unplug the connector with the engine running the scav fan kicks in?? With the engine off if you short the connections or run to ground the scav turns on too... Plug the connection back, tun the ignition on & off & the fan will stop & sort of reset....?!! Or run a hairdryer over the sensor beneath the "saddle" & it should come on??

Right! next problem, scavenger fan does not work by disconnecting, but does work by shorting it out.
So fans are ok.
Sensor seems to be ok as I put a meter across the sensor to check resistance as I put the end of the sensor in warm water. The resistance went down which indicates sensor is working. But at what point does the sensor tell the fans to switch on.
Is the sensor easy to get hold of and roughly how much?
Or am I better just connecting the fans to a switch so I can control when I want them. This may stop engine bay getting to hot before the fans kick in. I think some people have already done this.

As much as i know..? The scavenger fan only cuts in when the engine bay gets too hot through lack of air movement..
& possibly it was put there as an after thought to stop too much heat transference in this case from the engine bay up into the cab??
I'm not a big fan of putting an override switch in.. Though i did fit a warning flashing led should the fan come on...

Have you tried running a hair dryer over the sensor?? Yer scav fan function seems OK to me!!


I would be more tempted to concentrate on the vacuum system.... http://lushprojects.com/bongopartsmk2/c ... 1of02.html

I'm not convinced that what's connected leading up to the cold start solenoids is right either....

[stuc]

I would be more tempted to concentrate on the vacuum system.... http://lushprojects.com/bongopartsmk2/c ... 1of02.html

I'm not convinced that what's connected leading up to the cold start solenoids is right either....[/quote]

Cheers Jaylee, will try warming up the sensor with a heat gun or something.
Still unsure what problem these vac connections would be causing. Would like it how it should be but as the saying goes "if it's not broke".
Which ones are the cold start solenoids? To the left or centre. The drawing just says valve/solenoid. I think i would another Bongo alongside for me to compare the 2 so I can get my head round it.

[jaylee]

Which ones are the cold start solenoids?

These bad boys in the centre....



They control this puppy here...



... Which acts as a kind of cold start choke..

[jaylee]

Would like it how it should be but as the saying goes "if it's not broke".

I think it was more like dismantled & put back together wrong...?

[stuc]

I think best thing to do is get a look at another engine bay and see if I can put it right. If not may need a volunteer at the next bash I go to.
Ady?

[Northern Bongolow]

looking at another is always a good idea as long as thats original (ish).
or someone can do it over the phone while your stood there next to it. its not hard but its a tad hard to explain on here.

have a ride down here its not that far . ive got a few spare bits including the solenoids and pipe and the connectors.

the strange thing is how is it working like that and what has someone done to compensate for the lack of fast idle when warming up, if they have just wound up the throttle this must use a tad more fuel. what are the revs when its first started,then when its warmed up both without the throttle peddle, and does the aircon work.