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MK1 1.9D Berlingo Glow Plug Starting Problem
Hey Rustscrat,

Sorry its taken me so long to get back to you on this its been a hectic week, I've been using a wee bit of wire just to start it from cold.
The drawing that you've so kindly provided doesn't show a number of PINS that a present in the connector. So I'm just wondering if its the correct drawing. Also the male half of the connector has pin 6 present and intact. And I'm nearly sure I remember cleaning it the last time when this problem arose.
Here's a picture
[Image: IMG_20130908_104527.jpg]

And heres a picture of the two parts of the connector.

[Image: IMG_20130908_104518.jpg]

So that leads me to believe that the PIN is broken and missing. Now to the meat of the issue. I've found wire number 100 blue but I cannot find the other end of it. I'm also wondering if that is the correct wire that leads to the Relay?
Heres a picture.

[Image: IMG_20130908_105912.jpg]

There is a yellow wire present that's thicker than to other wires but not as thick as the BB10 and BB11 wires which I think you said go to the glow plugs themselves.
Heres a picture of that wire.

[Image: IMG_20130908_105156.jpg]

Could those wee markings on there have been "100" and it somehow wore away to that?
So what do you reckon mate? Should I just give it a wee nip join em up and see what happens?! That could potentially lead to problems eh?
Cheers again.

(04-09-2013, 06:46 PM)Rustscrat Wrote:  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]
[-] The following 1 user says Thank You to gilbertotron for this post:
  • whitebus

Wow I really don't know what to say about this. Last night while driving home late the glow plugs just started working again...
That leaves me thinking it must be a faulty unit. I really don't know.
The engine got a wee bit hot sitting in traffic so I switched it off while I wasn't moving. Next time I tried to start it the glow plug light came on the dash and has been work since.
I'm pretty sure this is for your van. Pin 6 could be an extra cable or pin they have put in and not used.
Blue wire 100 goes into the loom and is spliced to other cables which then becomes green 105 which goes to the relay (black 7 pin plug. Pin 4).
Here's the full set of diagrams listed for yours. :thumbsup:

[Image: 2m60a5e.png]

[Image: 2llygw5.png]

[Image: dghsu1.png]
2006 2.0hdi 600 with bench seat.  Cool
[-] The following 5 users say Thank You to Rustscrat for this post:
  • addo, brodfather11, gilbertotron, Ol'Jeffers, whitebus
Hi Rustscrat.
I have the same issue with connector ICA02 on my Mk1 1.9D. The glow plug relay unit is the type which has the 7 pin plug (one blank).
Could you please confirm if the wiring diagrams in posts 21 & 23 are correct for my van as I intend to bridge out the plug/socket arrangement.
Many thanks. John
If you could P/mail me your Vin No. I'll check it out. :thumbsup:
2006 2.0hdi 600 with bench seat.  Cool
[-] The following 1 user says Thank You to Rustscrat for this post:
  • whitebus
berlingoart, This is the same diagram for your van. Confusedalut:
2006 2.0hdi 600 with bench seat.  Cool
[-] The following 2 users say Thank You to Rustscrat for this post:
  • berlingoart, whitebus
(24-09-2013, 10:10 AM)Rustscrat Wrote:  berlingoart, This is the same diagram for your van. Confusedalut:

Many thanks Rustscrat - you are a true Gent.

This time tomorrow the rewire should have been completed.

[-] The following 1 user says Thank You to berlingoart for this post:
  • whitebus
No worries, did it solve the problem? :thumbsup:
2006 2.0hdi 600 with bench seat.  Cool
[-] The following 1 user says Thank You to Rustscrat for this post:
  • whitebus
Hi Rustscrat

Yes the van starts 1st time every time since bridging the wires and thanks again for your help.

[-] The following 2 users say Thank You to berlingoart for this post:
  • Rustscrat, whitebus
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.

Hi, I've been having problems starting my Berlingo 55 plate 1.9D for about a year now. It has had new starter motor, alternator, battery, glow plugs etc but the problem still remains. It will start after having the key turned til the light goes off but in winter this might have to be done 5 or 6 times and even then it only starts after 10-15 seconds. I've tried to locate this ICO2A thingy by following the two yellow wires from the fuse box but they disappear into the wing cavity. The diagram you show says (by the looks of it) that it should be somewhere under the headlight casing. I have found two things there, one is a round thing with only two thin wires going to it via a small plug and the other is above it and in a black square plastic box, possibly leads to something near the radiator though. Any help would be most welcome as i don't want to risk ruining the starter via another cold winter. Should i be following the BB10 and BB11 wires inside the van to find the ICO2A?, it's all too confusing for me. Changed the fuel filter only yesterday with help from my dad and felt as though i should've got some sort of Oscar for my efforts, that's how crap i am with cars/vans. Maybe you could upload a photo of the ICO2A? Thankyou.

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