Bongo Fury

Hi
Hope you are all ok.
(Please note English is not my first language).

First off all I would like to thank this forum and the shop for the help regarding issues that I had with my bongo and so far, I fixed them for the last 6 years.

I like challenges and fixing almost anything, but today I am stuck, any advice would be helpful.

Before I explain my problem, I would like to say that I have done my homework, for last 7 days and at least 14hours/day I tried to find the problem to fix it with YouTube, forums etc.…

I will try to explain the issue:

I was driving my bongo and 15minutes after I left my home:
car electrical system shuts off while driving car will not start.
Stopped in the safe place called the recovery.

Car completely dead, no lights no power no crank.

While I was waiting, I check online and found out that the fuse IG KEY60A blown (IGNITION). When the recovery mechanic arrived he checked the battery connection, battery, fuse, I told him to look the IG KEY60A that was blown, he had spar one, change it and as soon as he turn the key the fuse blown. Short circuit he told me.

Recovery brought back my Bongo at home.

The following are working: Battery 1 >12.30v, battery 2>12v30, Radio, Fog light, Rear light, Front light, Warning light, electric blind, door, interior light, all fuses tested.
ignition switch removed tear apart cleaned but still need to double check.
On the main battery I used a circuit tester, I removed the +lead far from the battery and I connected the circuit tester between the +lead and the +to the battery,
Light on= short circuit (hope I am right).

I Removed the follow one by one and back on they place to check if light will go off:
disconnected the starter, the alternator, neutral safety switch, ignition switch, all the fuses and the 3-relay close to the battery, one of them the lead is connected to the fuse IG KEY60A. nothing happened.
The 3 relays had been opened and checked.

Thanks to G8dhe for the electric manual.


I personally done the following work:
I had fuel starvation 5 months ago, new filter added plus inline filter that allowed me to see if it is block. Reservoir had been clean inside.
Glow plugs one years old.
exhaust manifold (skimmed by professional) repaired last summer (number 1 manifold stud broke).
Turbo waste gate actuator (not new) change last summer.
Second battery added 4years ago.
Starter motor solenoid contact changed 5 years ago.
Second-hand alternator changed 2 years ago.
And much more…

Thank you for taking the time to read my problem,
As today I do not know where to look to fix it, I do not want to give up right now as it will be my first fail of not be able to sort it out.
but I may have to see a car electrician.

couldn't add picture, i have tried few time and the size was too big.

Thanks.

Right given that the 60 Amp fuse is blowing and none of the other fuses are damaged or blowing it suggests a damaged wiring loom after the ignition switch to one of the other fuses below it in the fuse tree, there is nothing feed directly from the ignition switch so it points towards a damaged loom to the internal fuse block by the drivers knee.

Thank you for your very quick reply Geoff,

So if I understood the problem can only be between X-02, X-04 and A1-04.
Is that correct?

You may be able to narrow it down a bit, if the Ignition switch is moved ONLY to Ancillaries position 1 does the short appear ? If so then its on the ancillary wire to the fuse block X03.
If the short only appears when you move to the ON position 2 on the ignition switch then that points to a problem on the IG2 wire, again on the wire to the X03 fuse block.
If the short only appears when you move to the Start position 3 then that would point towards the IG1 and ST leads.

thanks again to point me where to look.
i will check, and i think from the position 1 the problem start.
i will do it now and test all the ancillary wire to the fuse block X03, and keep you updated.

thanks a lot you are giving me hope.

following your advice, yesterday i checked.

but before i did touch and inspected visually the wiring form the ignition switch, the fuses boxes.
i did reuse the blown 60amp fuse (home made fix, just 3 time).
the bongo started

tomorrow i will narrow it down, need to find this the short circuit.



pictures from switch ignition, clean and sand it.








fuse opened and checked.

Hi all
Update about my progress

I still have and I cannot find the short circuit on the fuse 60 IG KEY (X02 fuse box)
It just disappeared but I am not confident to use my bongo.

I have tested all the wiring from the switch to the fuse box (driver side X04 and front oneX02) and from the switch to the relays A104, one by one for continuity and short circuit they are all ok.

I start the engine, switch on everything and shake all the cable trying to recreate the short circuit.
nothing happened.

Any suggestion would be really appreciated, thanks in advance.

hi all

thanks Geoff for you help.
i am still trying to recreate the short circuit to be able to locate it, i have done and followed all your advice.
any idea?

thanks
keep safe.

There are the most annoying types of fault There really isn't much more you can do but inspect the wiring and clean things, you appear to have been pretty diligent in taking things apart and looking so one can only assume you have managed to disturb what ever was the cause. Its not been unknown for a stray wire end to make it into an ignition switch, but usually there is little trace after the event. The only other possibility is the loom itself has been caught somewhere and shorted but normally these types of fault are visible due to the wearing away of the loom covering and then the wire insulation. All I can suggest is keep a set of the spare larger fuses as well as the mini ones in the van as a precaution!

thanks Geoff

i will buy those large fuses as a spare.

i understand why this types of fault are annoying, personally this drive me crazy in one way and on other way i learnt a lot about car electricity for the last 3 weeks.

those are what i used trying to find the short.

Hi all,

After a year for not using my Bongo, I called an electrician,
he checked and found out that the connection needed a good clean.
He advised me to clean all the connection [front boot].
It is been over a month and all seems working fine….

Good news.

Good you're on the road again.
Electrical problems can sometimes take a while to pinpoint.
Last week I heard of a non-start 2.5d.
They changed the battery and checked fuel supply system.
But it was just a corroded spade connector.
No feed to the glowplug relay.