Black Box Glow plug Relay/Oil Light Buzzer

[pgra0909]

Hi Guys. Had my new T25 for about 7 months and TBH the Diesel engine hasn't let me down.... until now... however I think it's more electrical?? The black box in the engine bay which houses 2 relays and a load of wiring is a total mess. like this when I purchased it.

This last week or so when trying to start it it was just clicking and not turning over. thinking it was the starter I took it off and give it a good clean checked it directly linking it with a battery and jump leads and it was working fine. so refitted it and it was starting fine.. All good! I have noticed over the last month or so the temp gauge red light flickering but knowing the van wasn't over heating and driving great it didn't bother me to much. The last few days it's started clicking again... looking at all the messy wiring I checked for any lose connections and the van started up... turned it off and again it wouldn't start... just clicking.

All the wires in this box look a bit passed it and the smaller relay (53) looks the original so I'm gona order one of these plus the larger relay to rule that out... my question is could any of these relays cause it to just click and not turn over? the glow plug light comes on then off after a few seconds.

Also since looking at these wires the seemed to be a few not attached and looked like they have come off sensors? so I reattached them.. but as soon as I turn the ignition on I get a buzzer sound. engine not running!! even when I unattached them it still buzzes. I did top the oil up slightly as it was a little low. could this cause the buzzer to go off....? even if the engine isn't running?

I seem to be in a right pickle here.. I've attached a few pics. anyone know of anyone who can help? I live in Cramlington just outside Newcastle Upon Tyne. Don't mind paying! just need to get it going again.. summer is here!- Thanks for reading!

[colinthefox]

Oh dear, you seem to have a slection of minor problems.

Starter just clicking.
Temp gauge light flickering.
Messy wiring.
Wires to sensors not attached.
Buzzer of doom sounding.

Difficult to try to sort this lot out on the information so far.

I wouldn't think the relays are the cause of your problems, as it looks like the glow plugs are working OK

But first you might like to check all the heavy current connections. Remove, thoroughly clean, copper grease and tighten. It's a good job to do anyway. That is gear box to chassis by front gearbox mount, battery to chassis, battery to starter. There is also a short connection between the starter solenoid and motor body which can corrode. You can often see bad connections by operating the starter in the dark and looking for sparks. Be careful!

Temp light flickering can be bad earths. Check the earth crowns behind the glove box. My temp gauge light flickers when I charge my mobile phone from the ciggy lighter socket!

The rest could be a multitude of little things. You could really do with someone who knows their way around these having a look. JK's little orange manual has an alleged diesel wiring diagram. But you do need to sort the wiring problems out, because the sensors, buzzers, gauges etc are there to protect the engine.

If you could post photos of the wiring problems we might get a few clues.

[pgra0909]

Thanks for your reply Mate... it is a bit messy like.. not good ...I'm off work tomorrow so I'll get so good pics hopefully it might look clearer. thanks again

[pgra0909]

Hi, Sorrry I didn't get back.. called in to work so didn't get time.

Been on it today tho! I took the Starter motor out again and tried with a sapre battery...again and it works fine. attached all the wiring without putting the starter back and put an earth cable directly to the battery and it again worked fine. so guessing there was an issue with an earth somewhere. I put the starter back in place and put the extra earth cable directly from the starter to the battery and it now starts fine

As for the lose cables... with some digging around on here and the book you suggested I think I've managed to wire them up correctly. sort of....my temperature gauge is now working which it never did..

Still have the issue with the buzzer. however I'll start a new thread as I've taken a short video. Thanks for your help mate.