All kinds of problems

[Kez]

Where do i start?

I have an 03 1.9 non turbo. The clutch died, so a friend fitted a new one.
All back together and started up just fine. 2 warning lights:
water - seemed to go out when it got warner (perhaps an airlock that cured when the stat opened)
engine check - we tried a fault reader and there aren't any codes (?)

Turned off and went to start again - nothing. Display showing eco mode, plug heater light not working and speedo waving around at 80ish. Oh and sometimes the fuel gauge moves when the ignition is off.
did a bsi reset - no difference
tested for power at the starter and that looks ok. We found a battery live, ignition live and trigger, but still doesn't turn over.

We started it with a tow and the engine ran ok.. then stopped. We tried to start again, now it'll only run at high revs. Anything under 3.5k and it cuts out. Still won't start on the key and still the gauges are doing their own thing.

Ideas please?

[Gadgetman]

No codes?

Do you KNOW that the reader is communicating successfully with the ECU?
Older Berlingos use a weird communication protocol that most readers don't understand.
(Frankly, not even C-3P0 speaks that protocol)

[Kez]

Yes, it connects, but tells me there's nothing

[Civvic]

Where do i start?

I have an 03 1.9 non turbo. The clutch died, so a friend fitted a new one.
All back together and started up just fine. 2 warning lights:
water - seemed to go out when it got warner (perhaps an airlock that cured when the stat opened)
engine check - we tried a fault reader and there aren't any codes (?)

Turned off and went to start again - nothing. Display showing eco mode, plug heater light not working and speedo waving around at 80ish. Oh and sometimes the fuel gauge moves when the ignition is off.
did a bsi reset - no difference
tested for power at the starter and that looks ok. We found a battery live, ignition live and trigger, but still doesn't turn over.

We started it with a tow and the engine ran ok.. then stopped. We tried to start again, now it'll only run at high revs. Anything under 3.5k and it cuts out. Still won't start on the key and still the gauges are doing their own thing.

Ideas please?

Is it possible that the water level is low when its cold such that it is below sensor level before warming up and expanding up to above sensor level when hot? As for the engine light, check the re-installation of EGR vacuum pipes which if botched can lead to misfire and engine light. Also check if MAF sensor harness plug was fitted back properly into the socket, as well as the advance actuator solenoid.

[Kez]

Thank you, a few things to check
Will the vacuum pipe layout be in the haynes book? Because otherwise I have no idea where they are supposed to go, so wouldn't know if they were wrong

[oilyrag]

Hi, I had a Mazda 6 that developed a problem with gauges flying around, odd lights etc. and it turned out to be a poor earth connection at the battery - were any engine earth leads disturbed when the work was carried out? Double check the battery terminals are clean and tight and even try a jump lead from battery earth on to the engine block to rule out an earthing issue.
Good luck!

[Micoclarke]

I would second checking earthing. There's an important earth to gearbox casing iirc, which could have been disturbed with a clutch change?

[billskipton]

Like Micoclarke I would suggest earths. Anytime electrics start acting weird, always look at earths first - both the connection to the chassis/body and the connections to engine/gearbox/alyernator etc, especially any that have been disturbed during servicing

[Kez]

It was earths
Which ones, I'm not sure without crawling on the floor (isn't that what men are for haha). I put a jump lead on the battery to the engine block and it works again.
Thank you everyone for help. I really thought this was dead but it lives again

[Kez]

Just one last Q
The battery to gearbox earth is bolted to the top. I can see it and it seems to be fitted well. Is there anything else? Like one on the engine or something?