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Won't start after BSI relay repair
#1
Hi there,

Recently got myself a 2003 Berlingo 1.6 Petrol. Good nick but the central locking wasn't working right - would lock, but not unlock. I figured the problem was a dead relay on the BSI "relay & connector" section. I decided to replace all three relays while I was at it, so ordered some replacements and had them soldered on by a local repair shop.

After connecting the BSI back up, the van started but struggled to do so - never done that before. I turned off the ignition and tried again: now, nothing. The electric systems turn on fine (windows/wipers etc.), but there's no sound when starting - no struggling starter, no rapid clicking etc. I can hear a relay in the BSI click on though. The check engine light is now on; it wasn't before.

Tried charging the battery as van had been sat for a while; no joy.

Tried BSI reset a couple times.

Checked fuses in BSI & ECU.

Checked fault codes with OBD scanner: P0261, P0264, P0267, P0270 ("Cylinder 1-4 Injector Circuits Low") & P0444 (Evaporative Emission System Purge Control Valve Circuit Open").

Normally I'd assume that it was the relay replacement was at fault - the soldering job wasn't brilliant. But that wouldn't explain why the van started initially, or why it struggled. Plus I can hear the BSI relay working. I've ordered a second hand relay/connector board to try swapping it out but it won't be here until next week.

Maybe the starter has gone and it's just a coincidence? Haynes manual has a guide for testing voltages at the solenoid, starter etc. but unhelpfully doesn't say where the bits are - I'm a practical guy but don't know much about cars!

Any suggestions much appreciated!

(on the plus side, at least the central locking works now Big Grin)
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#2
Just to finish up this story:

Established it was the starter after checking voltages on ignition. Starter replaced - a relatively easy job, as it turned out - and now seems to be running fine.

Fault codes remained on, but I cleared them this morning and they didn't reappear during a short drive.

So seems that control board repairs were not at fault - starter death just a coincidence? As for the fault codes - maybe they were just randomly thrown by an unhappy van? Will keep an eye.
[-] The following 2 users say Thank You to SteakAndAle for this post:
  • Art b, cancunia
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#3
Glad you git it fixed. Thanks for the update, it's always good to know how things progress.
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#4
Yes always nice to get an update, I would have blamed the BSI as well. The problematic starting must have polished off the starter
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#5
Yeah, I kept talking myself in circles. In general if you mess with X and then Y breaks, it's reasonable to assume that messing X is the cause! But a damaged BSI wouldn't allow it start at all, or cause a starter to struggle. Repeated this conversation with myself for several days, and was terrified I was going to have to replace the BSI (+ hence ECU etc.) entirely !

Fault codes did not return on a ~300mi round trip so all seems well on that front.
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