Bongo Fury

I've not had a great Bongo summer really - overheating, not starting, overheating, not starting...

Been at Discount Trucks twice for the overheating, first time it had head pressure and other tests then a new water pump.. over heated again a few hundred miles later and went back for more pressure tests etc but no obvious culprit so was given a dose of steel seal to see if it sorted it.

No idea if the starting problems were coolant related but after a new battery, new glow plugs and new contacts in starter motor it would start better than it ever had on the first turn.

Until the last week when after driving to the Heritage Motor Museum at Gaydon it wouldnt start again. Not even a peep, lights on, glowplug lights off, turn and click. Nothing. No attempt to even turn.

Ended up being recovered by green flag (very efficient) on the back of a flat bed. Mechanic said "Starter motor at fault" which was a suprise (but not from the symptoms i guess).

Now as i said i'd replaced the contacts and plunger about 3 months ago - is it possible i've got duds? Or is it more likely the motor is dead?

This is what the contacts/plunger look like now...







I did notice the wire on the back of the motor was exposed though...



Could this be anything to do with it?

Sorry for the long post but i'm losing faith in the Bongo - need it to be more reliable that it has been in the last few months. Already spent over £500 on the above bits and dont seem any further forward Any words of wisdom or glimmers of light would be greatly appreciated.

PS - again might be a red herring but when at Discount Trucks it was left on pressure test for the whole weekend without any obvious leak being seen but would not start afterwards. Said this was due to vapour behind one of the glow plugs which once removed and replaced it was fine again. A little worrying but the head test was fine and the steel seal was a belt and braces thing to prevent it happening again. Could this account for the non starting?

Thanks in advance

Is it possible that the large contact has moved slightly under or since tightening? That might account for the uneven wear on it and the excess wear on the other one. I found the alignment a bit hit and miss when I did mine.

Thanks for the suggestion - i'll check that, although currently it was more miss than hit with no turning at all!

i would try and clean the contacts up to flatten them off again, and the underside of the plunger,align everything carefully/evenly, and test. nothing to loose. test the solenoid is pulling in the plunger, or hear it click towards the contacts.

Recently and for the first time, saw a starter motor that had actually failed, it caused huge battery draw when the key was turned to the point of melting cabling, (good old AA, keep turning the key til they see smoke!), so be aware that if the motor is in early stages of failing then it will kill contacts etc. The vehicle displayed similar sypmtoms, maybe time to consider replacing the whole unit.

Julian

Just so you know, today I cleaned up the contacts and raised then ever so slightly and I taped up the exposed wire.
I also noticed that the wiring connected to the left hand external contact thread was quite dirty/coroded - so brightened that up too.
All refitted in the fading light and started she did!
Hoping this is an end to the tale - and not just a warning!
Cheers

dblake wrote:Just so you know, today I cleaned up the contacts and raised then ever so slightly and I taped up the exposed wire.
I also noticed that the wiring connected to the left hand external contact thread was quite dirty/coroded - so brightened that up too.
All refitted in the fading light and started she did!
Hoping this is an end to the tale - and not just a warning!
Cheers

Fingers crossed for you dude: could be you are rounding the corner.

Keep us posted, .

Daz

Okay, bit of an update:
Starting great still, first time every time. Better than my more modern cars really lol
Bad news is it overheated again very disappointed given the money already spent on 'fixing' that.
Had Simon from Contract Mechanics over today to take a look and his experienced verdict was a head problem
That'll be my rainy day fund used up then

Hi. I know how you feel, I have been having problems with my Bongo since October 2011. It runs for awile anything from 15 mineutes to one hour. It has been into four garages one of those was Simon at contract mechanics who had it for thee days but could not find the problem. I have changed the engine temp sensor. fuel filter. ignition coil yesterday.
Next is the cam sensor after the holiday. After that I dont know what to do. Once its fixed I will trade it in for a VW. At least they have dealers in every major town. A few of you peeps out there have tried to help. But I am still banging my head up a brick wall. . John