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MK1 1.9D Berlingo Glow Plug Starting Problem
#11
Ok I'm looking at the same thing but how do I gain access to the connector? Take the tyre off and go in that way or somewhere else. Rather annoyingly I've found we've had a mouse in the fusebox storing wheat so is it possible to lift the top of the fusebox out so I can see if any of the wires have been chewed?

Answers to either would be really helpful
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#12
(17-01-2012, 07:36 PM)Rustscrat Wrote:  
(17-01-2012, 07:26 AM)magnum Wrote:  
(11-01-2012, 10:54 PM)adam3rdcanvey Wrote:  The glowplugs are likely to be burned out. Have they ever been changed?

Thanks Adam, I can start the van immediately everytime if I give a direct supply to the glow plugs. I changed the start relay and the temperature control sensor, the fault only happens on the odd occasions. I haven't chaged the glow plugs because the van will start ok on a direct supply which would suggest that the glow plugs are ok. I took the van to the local citroen garage who said that they had cleaned one of the block connectors that seemed dirty but the problem contiues.

Hi, I had a similar problem with bad starting on my old 98 mk1. This turned out to be corroded connections in IC02A connector of the engine bay. "Where is this?" I hear you say - well if I can remember it is fastened on the passenger side inner wing of the engine bay below the battery. This unscrews. I bypassed this connector by taking the connection from the fuse box straight to the glow plug relay unit.
There are two yellow wires (which come out of the fusebox) about 3mm dia marked BB10 & BB11. After these go through the IC02a connection they become black with the same markings and connect to the relay.
Good Luck Confusedalut:
If these don't match your van, let me know your RPO number and engine type.
[Image: 2qvv1mx.png][Image: 20koldd.png][Image: 4l2jbp.png]
Thanks so much for this Rustscrat.
It took me awhile to figure out where the connector was and the it didnt want to screw apart for me.
But once I gave it a bit of gentle persuasion with a screwdriver she came apart lovely. I pulled to connector apart and cleaned all the pins stuck her back together and hey presto problem solved. I was about to go buy a new relay so you've saved me money too.
Many thanks.
[-] The following 3 users say Thank You to gilbertotron for this post:
  • rublehousen, Rustscrat, whitebus
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#13
(10-06-2013, 06:25 PM)gilbertotron Wrote:  
(17-01-2012, 07:36 PM)Rustscrat Wrote:  
(17-01-2012, 07:26 AM)magnum Wrote:  
(11-01-2012, 10:54 PM)adam3rdcanvey Wrote:  The glowplugs are likely to be burned out. Have they ever been changed?

Thanks Adam, I can start the van immediately everytime if I give a direct supply to the glow plugs. I changed the start relay and the temperature control sensor, the fault only happens on the odd occasions. I haven't chaged the glow plugs because the van will start ok on a direct supply which would suggest that the glow plugs are ok. I took the van to the local citroen garage who said that they had cleaned one of the block connectors that seemed dirty but the problem contiues.

Hi, I had a similar problem with bad starting on my old 98 mk1. This turned out to be corroded connections in IC02A connector of the engine bay. "Where is this?" I hear you say - well if I can remember it is fastened on the passenger side inner wing of the engine bay below the battery. This unscrews. I bypassed this connector by taking the connection from the fuse box straight to the glow plug relay unit.
There are two yellow wires (which come out of the fusebox) about 3mm dia marked BB10 & BB11. After these go through the IC02a connection they become black with the same markings and connect to the relay.
Good Luck Confusedalut:
If these don't match your van, let me know your RPO number and engine type.
[Image: 2qvv1mx.png][Image: 20koldd.png][Image: 4l2jbp.png]
Thanks so much for this Rustscrat.
It took me awhile to figure out where the connector was and the it didnt want to screw apart for me.
But once I gave it a bit of gentle persuasion with a screwdriver she came apart lovely. I pulled to connector apart and cleaned all the pins stuck her back together and hey presto problem solved. I was about to go buy a new relay so you've saved me money too.
Many thanks.

No worries, your welcome. :thumbsup:
2006 2.0hdi 600 with bench seat.  Cool
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#14
Hi, may I ask a question? When you guys spoke about the bad connection below the battery the one that unscrews, are you talking about the two round connectors behind the battery and ECU? If so it looks like a multi-plug to me is this why the glowplug relay is not pulling in and the light is not on the dash ?

Hoping you can help.
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#15
Yep it's possible. Give it an inspection to make sure it's ok. :thumbsup:
2006 2.0hdi 600 with bench seat.  Cool
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#16
Hi again.

After fixing this by cleaning the connectors the problem arose again this weekend. So thinking "I know what is it I'll do take her apart and clean it again" I took the connector apart to find that one of the pins was broken. Bummer. So I presume that this broken connector must have been the one to intiate the glow plugs. My question is this, can I just cut the corresponding wire and join them directly rather than through the connector. And if so, which wires are they? I tried to follow the wiring diagram that Rusty so generously provided, but I don't really know what all the symbols mean and I'm loath to cut any wire until I can be sure I can Identify its purpose. From the diagram it seems to me that its wire number 100 coming from the ignition but to what do I join this?
Thanks again for any help, its much appreciated. If i can't do it this way I'll be forced to wire up a a wee button in the cab I guess...
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#17
The two wires you want to join are: (taken from post 4)

"There are two yellow wires (which come out of the fuse box) about 3MM dia marked BB10 & BB11. After these go through the IC02a connection they become black with the same markings and connect to the relay."

If it's wire 100 (blue going into IC02a pin 7, green coming out) you will definitely have to join this as it controls the relay.
Confusedalut:
2006 2.0hdi 600 with bench seat.  Cool
[-] The following 2 users say Thank You to Rustscrat for this post:
  • gilbertotron, whitebus
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#18
Hey Rustscrat, thanks for getting back to me so quickly. So I've attached a picture of the connector with the broken pin. It appears to me to be pin number 3.
So if I understand what you're saying. I need to cut wire 100 blue before and join with the same number yellow after?
Only problem is I can't find a yellow 100. There's one marked with multiple " " " markings. That might be it?

[Image: IMG_20130902_184322.jpg]

(02-09-2013, 02:26 PM)Rustscrat Wrote:  The two wires you want to join are: (taken from post 4)

"There are two yellow wires (which come out of the fuse box) about 3MM dia marked BB10 & BB11. After these go through the IC02a connection they become black with the same markings and connect to the relay."

If it's wire 100 (blue going into IC02a pin 7, green coming out) you will definitely have to join this as it controls the relay.
Confusedalut:
[-] The following 1 user says Thank You to gilbertotron for this post:
  • whitebus
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#19
Here's your picture with the numbers of the pins. I'm presuming it's pin 1 thats snapped off.
Lets make sure that we are both talking about the same plug & socket arrangement, can you P/Mail me your Vin No. so I can get the correct drawing. :thumbsup:

[Image: 2ngzl9i.png]
2006 2.0hdi 600 with bench seat.  Cool
[-] The following 2 users say Thank You to Rustscrat for this post:
  • gilbertotron, whitebus
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#20
Ok, this is the pin out for your van.
As you can see, pin 6 and pin 16 are not used.

Pin 1 and pin 2 carry the main current for the glow plugs.
Re colours - Jn = Yellow. Nr = Black. Be = Blue. Gr = Grey. Ve = Green. Rg = Red.

The numbers of the actual wires will be printed on the insulation but you need good eyes and you might have to strip back the binding to see these. To me, it looks like there is damage on pin 1.

[Image: 33aqrl5.png]
2006 2.0hdi 600 with bench seat.  Cool
[-] The following 2 users say Thank You to Rustscrat for this post:
  • gilbertotron, ron
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