Starting problems / glow plug issue

[Lloydy]

I have recently replaced my plugs with 4 NGK's after suffering real starting problems (took ages then lots of smoke).

Problem solved... Even in the coldest weather ELMO started perfectly on the key turn.

Problem is.... 2 1/2 weeks in and the same problem has started again!!!??? I have tried to usual wait a few seconds ect. but it makes no difference. The batteries seem fine and i can hear a click from the main battery area about 10 seconds after the light goes out which i assume is the glow plug relay?

I am pulling my hair out now and after a series of problems with ELMO am having nasty thoughts of letting it go! I use it for work and so it needs to be reliable!

Having said that, i really enjoy working on it and the sense of satisfaction from a successfull repair is great. Just cant get my head around this one.

Any advice would be much appreciated.

Lloydy

[francophile1947]

First thing is to check that power is getting to the glow plugs - maybe the fusible link has burned out.

[Trouble at t'Mill]

Very easy to check using a voltmeter or a lamp with fly leads - just lift the driver's seat.

[Lloydy]

Hi all,

Thanks for the replies.

Sorry it has taken me so long to reply, have been away visiting family abroad for a week..... They have no internet, whats that all about!?

I have now checked the heater plug rail and can confirm the NO current is reaching that point. The relay behind the battery fuses seems to click but i havnt had time tonight to get the battery out and check that.

Any further suggestions would be much appreciated as i am tackling it again before the weekend.

Kindest regards,

Lloydy

[westonwarrior]

If the relay is ok it may be the fusable link this is a short cloth type wire connected to the battery and a normal wire pluged in the other end its about 2-3 inches long from memory

I would unplug it at the wire end and test it for power when turning on the ignition.

If it is blown it can be replaced with a fused link with the correct connector fitted it will need about a 25 -30 amp fues in it.

[bigdaddycain]

Could the glowplug rail have arced on the manifold causing the fuse to blow initially?

[haydn callow]

may sound daft...but....are you testing the rail with the ignition ON ??

[teenmal]

Hi Lloydy,if the relay clicks this does not mean that it is fully functional,it only tell that it is being energised(excited).
The relay could have broken/burnt contacts.

Ps dont be put off by the excited bit.

Cheers Mal..

[Lloydy]

Hi all,

Thanks for the further replies!

The rail was checked with the ignition on and my next job would seem to be checking the relay properly and also the fuseable link wire as described. I cant see how the glow plug rail could have touched the manifold but i will double check that nothing has come loose to cause this.

I will do the checks and update you all! Please check back in a couple of days as i am sure i will need further help!!!

Thanks again everyone, this forum is one of the many great things that is owning a Bongo.

Lloydy

[Lloydy]

ALL FIXED!!

There were two problems.

1) The cable that feeds the glow plug rail where it joins the possitive terminal was melting. I replaced this section 3 times before i realised there must be a cause.... This lead me to finding problem 2!

2) Took me ages!!!! Having recently changed my glowplugs for some nice new NGK's i focused my attention there to see if i had made a boo boo..... Well, it turns out that the top end of the NGK's were a little shorter than the Jap ones. The inside bit is the same and they work fine but due to the top measurement the glow plug rail was rubbing on the metal piping underneath it. It took a couple of weeks but the rubber on the rail eventually rubbed through and hey presto, earhed out the rail causing (1) to melt!!!

Well anyway, i carefully bent the metal tubing away from the rail and ELMO is back on top form again....For now!

Thanks for all your help and i hope this thread helps others suffering similar problems.

Lloydy

[mikeonb4c]

Great news Lloydy and glad ELMO has her fire back. Very satisfying when you track down the problem properly - a bit like getting a splinter out

[missfixit70]

Nice one Lloydy Maybe see you at the Wookey Hole meet in a couple of weeks?