Bongo Fury

Can't fathom this one out. I have had a few previous posts on starting probs in that engine would turn over and over and eventually starting with loads of smoke and chokey diesel fumes, running rough for a half minute then fine. Would start fine again until engine was dead cold and prob came back.
Replaced glow plugs (they looked like they had been chewed by rats) - which made an immediate difference. Then went on a long run and it started playing up again with same probs as before.
Replaced battery as other hardly had enough to turn over the engine after all the probs - made immediate difference and have been using the Bongo for a couple of weeks on short runs and no probs starting even in the v. cold weather we have been having until I went on a long run (swindon to cardiff). Engine cooled to dead cold during the day and has same prob as before starting. Managed to get it going and got home fine but same probs as before this morning.

Only thing i can think off is in replacing glow plugs and battery I had to dis the power to everything and once power back on again probs seem to go away (but at the same time i did fix stuff).

Is it possible that on a long run - i.e. engine stays hot for a long time - something is triggered which affects starting and when dis'ing the battery it resets whatever it is that i causing the probs.

Its driving me nuts and so disappointing when it happens.
sorry for length of message

It does sound a bit glowplug related (es. since your remedies produced immediate imporvement). Did you buy a quality make of replacement glowplugs as peeps who bought cheaper brands have been disappointed with them (NGK are good I believe). Are you waiting for orange glow light to go out before turning the key (best to wait a further short period too, many say)? Is it possible the glowplug relay is not working properly (I'm no expert no what effect this could have but no doubt others will be along to advise).

Good luck - keep us posted (its an interesting case)

sounds a fuel side of things to me..... EGR could be playing up or fuel delivery....do you know when the filter was last changed and Banjo cleared out?......
As your Swindon way...... it would be worth giving Tom a Call at Bell Hill Garage....

Basically, it sounds like it doesn't like starting from cold, have you checked the glow plug relay? is the glow plug rail getting voltage every time you turn the key? could be somethnig not tightened properly from when you changed the plugs?

I used NGK glowplugs bought through this site.
Yes it could be fuel and no i haven't changed filters or cleaned banjos (whatever they might be) but willing to have a go.

The thing that really puzzles me is that both times i have fixed it all was working absolutely great will oads of small runs (20 miles or less) and then i had done a long journey (50+miles) and probs came back. First fix was glow plugs and then new battery - poss sticky relay?

I have noticed that on a long run the engine becomes hotter then on a shortish one (temp guage at 1/4 for short and 1/2 for long) - possible clue?

I'll check voltage rail between glow plug bus bar and chassis next time i go outside but not tonight as its minus 1000 outside.

JonWM wrote:I used NGK glowplugs bought through this site.
Yes it could be fuel and no i haven't changed filters or cleaned banjos (whatever they might be) but willing to have a go.

The thing that really puzzles me is that both times i have fixed it all was working absolutely great will oads of small runs (20 miles or less) and then i had done a long journey (50+miles) and probs came back. First fix was glow plugs and then new battery - poss sticky relay?

I have noticed that on a long run the engine becomes hotter then on a shortish one (temp guage at 1/4 for short and 1/2 for long) - possible clue?I'll check voltage rail between glow plug bus bar and chassis next time i go outside but not tonight as its minus 1000 outside.

If your engine isn't getting above 1/4 on the (unmodified?) temp gauge after 20 miles, there's possibly something not quite right (I suppose it'll take longer for the engine to warm up in the colder temps, especially if you've got heaters on taking the heat out of the cooling system) , but at least it's getting up to temp on a longer run. I reckon the stat may have been "modified" by drilling it or removing the gubbins so it takes longer to warm up?
I don't think this will have a bearing on the starting problems though.

Were the new plugs the same length as the ones that came out? could be it's shorting out on the rail somewhere if the relay turns out to be ok.

Hi Kirsty,

The glow plugs were the same length as the ones removed.
Bizzarely it started first time this morning (and it was -3 at the time) - lets see how it goes tonight when I go home.

I reckon it must be an intermittent fault which seems to surface after a long run (vibration at higher and constant engine/road speeds?).

As you say I shall do a voltage test next time it fails to start which will narrow it down massively and get back to you.

tank breather vacum after long run????????????

next time try releasing the cap on tank if it does it

Will give that a go too. Although i hadn't noticed any suction when filling up.

I'll try anything to get to the bottom of this prob.