starter motor problem

nfn · Post by **nfn** » Thu Dec 27, 2007 3:09 pm

My bongo is no longer springing to life every time the key is turned. Perhaps once in every 10 starts, the starter motor does not turn. The battery is fine, and if I turn the key again it will start as normal. I assume that the starter or starter solenoid is on its way out, and that it will get worse. I once had a VW camper with identical symptoms, and I kept it going for a few months either by whacking the solenoid with a spanner, or by bypassing the solenoid with a screw driver (with a well insulated handle!). After that stopped working, I resorted to push starting. The film "Little Miss Sunshine" really brought back memories of this procedure! Anyhow, I'm having trouble even finding the starter on my bongo. My guess is that it resides on the driver's side, at the back of the engine, partly obscured by the big air hose from the air cleaner across to the turbo. If I'm looking at the right thing, it only appears to consist of one cylinder -- there is no solenoid on the outside of the starter casing. Is it possible to test the solenoid on a bongo by bypassing it with a screw driver? If so, where do I stick the screw driver?

I will get it looked at by a mechanic in the new year -- unfortunately reconditioned starters don't look cheap.

moonshine · Post by **moonshine** » Thu Dec 27, 2007 4:10 pm

If your problem is simply that the starter clicks when you turn the key, but the motor doesn't turn, then you have the common problem with Bongo starters. It is quite easy to cure, fortunately, and not too expensive either. I did mine back in the summer, and as far as I can remember it cost me less than £20. All that is wrong is the solenoid contacts are burnt, and these are easily obtainable.

There is rarely any need to go down the recon-starter route, but many garages may suggest it as they can't be bothered to strip yours and replace the contacts.

The starter motor is not difficult to remove, just a couple of cables and three bolts. You are right about where it lives. If you do it yourself, don't forget to disconnect the battery before you begin, as one of the cables you have to disconnect is live at all times. After disconnecting the battery, remove the air hose, complete with the top of the air cleaner, and removing the starter motor is all straight forward from then on. Three small set screws hold the solenoid end cap on, undo these, pull out the plunger, and replace the contact. Put it all back together, replace the starter, and your Bongo will start first time every time.

nfn · Post by **nfn** » Thu Dec 27, 2007 4:21 pm

Thanks Moonshine -- I will listen for a click next time.

shakey · Post by **shakey** » Thu Dec 27, 2007 5:56 pm

Solonoid kit details on page 1 of compatible parts string. Shakey.

bigdaddycain · Post by **bigdaddycain** » Thu Dec 27, 2007 11:54 pm

Mr Maynard? Can moonshine's post become a factsheet please?

That was some great direct info there moonshine...well done

Post by **Ian** » Fri Dec 28, 2007 10:30 am

bigdaddycain wrote:Mr Maynard? Can moonshine's post become a factsheet please?

Consider it done. Is there any other info out there that can be incorporated?

mikeonb4c · Post by **mikeonb4c** » Fri Dec 28, 2007 11:27 am

Moonshine wrote it up in greater detail I think when he first did the job. It should be on an old thread. I kept this bit of correspondence with him from that time, which suggests it was around May/June last year.

Finally got round to changing the contacts in my starter motor. Excellent service from Auto Electrical Supplies of Southampton, who sent me the relevant parts within 24 hours of ordering them. Very helpful and knew exactly what I needed. Bongo now starts first time every time, and no more clicks!

moonshine
Bongolier

Joined: 26 Nov 2005
Posts: 470
Location: Stanstead Abbotts, Herts
Posted: Thu Jun 28, 2007 10:40 pm Post subject:

Very straightforward, Mike. Starter is held in by three bolts which are quite easy to remove using a socket wrench. Procedure as follows;

1. Disconnect the battery.
2. Remove starter motor connections, 1 spade connector and one nut.
3. Remove top of air cleaner and the large attached inlet hose.
4. Unbolt starter. Starter motor can now be jiggled out of vehicle.
5. Remove three small bolts securing the end plate of the solenoid.
6. Lift off plate and pull out solenoid plunger.
7. Unbolt contacts taking care to note where insulators and washers go.

Putting it back together is simply a reversal of above.

Once it's all back together, re-connect the battery and starting is once more, first time every time.

Moonshine - any thoughts on the above etc.?

moonshine · Post by **moonshine** » Fri Dec 28, 2007 11:51 am

Hi Mike,

Thanks for finding that old thread, it saved me looking for it myself which I intended to do when I had time. I am quite happy for it to be used as a fact-sheet if it will help somebody.

This is the website for the suppliers; http://www.aes-gb.com

Colin.

patnben · Post by **patnben** » Fri Dec 28, 2007 12:38 pm

Don't forget that if you have the factory fitted winter pack, the starter
and solenoid are a heavy duty type and it's almost impossible to
replace the solenoid contacts, and I could not find a new or recon
solenoid except in America.

You can can simply replace the heavy duty kit with the standard duty
starter and solenoid.

moonshine · Post by **moonshine** » Fri Dec 28, 2007 6:21 pm

Well you learn something every day. I didn't know there was more than one type of starter motor fitted. Mine is just the standard type as I don't have the winter pack.

bigdaddycain · Post by **bigdaddycain** » Fri Dec 28, 2007 7:02 pm

Me neither..i didn't know there were two different types either.... Cheers patnben

mikeonb4c · Post by **mikeonb4c** » Fri Dec 28, 2007 8:01 pm

Excellent thread - thanks again to moonshine +patnben for the cherry on the top. Should make a v useful factsheet

patnben · Post by **patnben** » Sat Dec 29, 2007 11:31 am

A few more facts which may help.

The standard starter is 2 kW, the heavy duty one is 2.2 kW.

The 2.2 kW starter has the solenoid on top of the starter and is clearly
visible, the standard solenoid is mounted in a different position and not
so visable.

The heavy duty solenoid is a 1mm thick cylinder which has the end rolled
over to secure the internal mechanisms, short of sawing it in half with a
hacksaw, there is no way to dismantle it.

The heavy duty starter has a support bearing at the end of the bendix
shaft, the standard starter does not.

The heavy duty starter has a better arrangement to force the pinion
onto the starter ring whereas the standard starter relies more on the
rotational inertia to engage the starter ring.

I spent many hours googling for a new heavy duty solenoid and failed
to find one in this country, I have to admit that I'm no expert so others
may be more competant, or lucky, and find a local source.

In the end I bought a complete standard starter and solenoid for around
140 pounds, which looked brand new, arrived next morning, and I fitted
it within a couple of hours. No problem since.

nobber · Post by **nobber** » Thu Jan 24, 2008 11:10 am

moonshine wrote:Hi Mike,

Thanks for finding that old thread, it saved me looking for it myself which I intended to do when I had time. I am quite happy for it to be used as a fact-sheet if it will help somebody.

This is the website for the suppliers; http://www.aes-gb.com

Colin.

I have just received my new contact and plunger from these chaps but there just seems to be one (the smaller) contact and the plunger but my starter has 2 contacts... they say that is all they ever supply is this correct?

moonshine · Post by **moonshine** » Thu Jan 24, 2008 6:05 pm

Hi nobber,

That is all they supplied to me, and I queried it too. I fitted the contact supplied, cleaned up the other one, and put it all back together. It's been fine ever since, and starts first time every time now.

However, in a different thread, (solenoid repair kits) someone has contacted AES and they are going to try to source a second contact.