Bongo Fury

OK........long story short; sequence of events.......
1.Apr 06 import Bongo from Japan.
2. 12 months or so of trouble-free Bongoing.
3. May Bank hol weekend 07, van overheats, RAC diagnose thermostat.
4. Fit new stat, bleed system.
5. 1 month of trouble free motoring.
6. Whitsun bank hol weekend, van overheats randomly, stop, check water level, avoid scalding, release pressure from header tank - water level OK, so drive home (40+ miles) keeping an eye on temp gauge running @ 12.00 instead of 11.30.
7. Early June - start getting puffs of white smoke through exhaust on start up, so do CO test on exp. tank to discover head/gasket u/s
8. 1st week of June; Order head gasket set.
9. 2nd week; Remove head - signs of cracking.
10. 3rd week; Pressure test head.........bad news.
11. 4th week; Order new head
12. End of June; fit new head & gasket - happy days? Not really!
Unlucky 13. Van still puffing white smoke on start up; not losing water, not leaking CO into water, running fine when warm, no lack of power, but lumpy until white smoke clears.
Answers on a postcard to desperate bongo owners club, South Wales branch!
Any advice, no matter how obscure, appreciated!
btw, 2.5TD, bog-standard WLT Bongo engine.

White smoke can be unburnt fuel, so I would check glowplugs, especially as engine is lumpy until warmed up.

sounds feasible........any one had similar prob?

Obvious question- Do you wait for the glow light to go out before engaging the starter?

This really sounds like a duff glowplug/ relay. Lots here on checking the electrics.

Check the relay and plugs.

Bonza

Also check the rail-thing that connects the glow plugs to the power. Get a bulb or multimeter & connect it between earth & the feed for plugs - should show power while the glow plug light on the dashboard is on & then I believe it stays on for a minute or so after the engine has started.

top of the list....cheers

get your main battery tested as well.
bongo needs 560 cranking amps to start,
ours was 440 so got a new one. check that the relay clicks on the glowplugs turn on ing and after 30 sec or so c=should hear a dull clunk from bonnet.

Getting glowplugs tested tomorrow.
Mechanic who fitted new head & gasket set for
me, assures me that he DID connect everything in glow plug
circuit, so hopefully its' only one or two new plugs!