1996 Boxer Harmony 2ltr Petrol

Bought this van early April, 20 years old but extremely low mileage (27600) and in great condition inside and out. Fitted with TOAD Ai606 Cat 1 Alarm system - soon to be removed. Very pleased with the vehicle when I first drove it home (50 miles) and it's been sat on the drive since then. I've kept both batteries charged and have started it up at least weekly. Now, for some reason unknown, the beast just refuses to start. The van came with a comprehensive set of AutoSleepers habitation manuals but unfortunately nothing on the mechanical side of the base vehicle and I am completely flummoxed as to where to start looking. I think that the problem may be fuel related (or lack of it reaching the engine) yet it has nearly a full tank of petrol and turns over as it should and the cut-off valve by the battery is down.  Does anyone out there know if there are any fuses that could cause fuel starvation, or indeed anything at all that could prevent the beast starting? I've located the fuel cut-off valve, are there any other similar cut-offs tucked away? Could it be a faulty crankshaft/camshaft sensor? I'm nearly at wit's end, stuck with a vehicle I can't use. HEEEELP!! Regards to all. Grahame

Not the same vehicle by a long chalk but my V70 was acting in the same way and it turned out to be a busted fuel pump.

Hi,
This van is fitted with an electric immobiliser built into the key, you should have received a red master key as well as the normal one which is used to program new keys. The immobiliser works through the ecu and can be bypassed by a specialist company. It is possible that your toad alarm is also preventing starting. First try an alternative key, then its round to checking fuel delivery etc. which really needs a mechanic. There is a plug in diagnostic socket but it is useless and unless you have a flashing fault light it will have nothing to read. Finding a mechanic who is able to understand this old technology will be difficult. Do the dashboard lights, oil and ignition come on with the key and you should also hear the fuel pump running,
Chris

Thanks Andy - sounds expensive!

Thanks also Chris. Unfortunately I only received 1 set of keys when I bought it - no red master key. I suspect TOAD has something to do with it and am going to get this removed. Dashboard lights up and gauges swing round as normal when key is turned; haven't listened for pump - will do tomorrow. As far as the key is concerned, it looks just like any ignition key from the old days. As I have no info whatsoever on the base vehicle, I'm reliant on information supplied by people such as yourself on the ASOF Site. Thank you. Grahame

Grahame T wrote:Thanks Andy - sounds expensive!

It was Grahame.
 
£499 expensive.

Hi,
My van was a 2001 petrol and when I had an idle speed fault I went round the houses trying to get it sorted. The trouble is that the mechanics who were familiar with this engine have now all retired, its ecu and controls are now out of date. If you disconnect the engine battery for a few minutes this resets the ecu which is worth trying. Removing the ecu for testing is fairly straight forward, the immobiliser part can be disconnected if you wish, ecu testers can be found if you google, mine cost me £70 to be tested by a company at Rugely. If you are getting an expert in to remove the alarm he may be able to run a few checks for you. If you take a plug lead off and fit it to a spare plug you could test for a spark, if ok you could remove a plug to see if its wet, be aware that if there is a lot of unburnt petrol in the engine this can damage the catalytic converter when the engine fires,
Might be worth joining green flag and calling them out,
Good luck,
Chris

Chris. TVM for your most welcome and helpful suggestions. Yes, I shall be getting an "expert" in to remove the alarm and I shall be pumping him for any info he can give. As I've already said, my main problem is lack of info and I'm going to purchase a Russek manual to get at least some basic info on the engine. Once again, thanks for your help Chris, much appreciated. Grahame

Nice to see someone getting a response from Grahame, he ignored Mojo and me when we replied to him on an earlier, related thread.

Frank

Frank . Thanks for your comment. Please accept my sincere apologies for not acknowledging your response to my query, it was not intentional. My apologies go also to Mojo who also responded to my query. Regards, thanks and best wishes. Grahame

Totally different vehicle.......but, I had a similar problem earlier this year, dash lights came on after immobiliser was touched,but turn key..... and nothing !!
Replaced ignition switch, start ok....great....for a day or two..
Then no go....Had Clifford alarm removed professionally, at great expense....ok for couple of days, then problem returned.  Removal of above alarm still left a Laserline immobiliser, which I  then started to worry about......   Took vehicle to local garage to have new replacement fan belt fitted, and got them to remove all connections to starter motor, clean them up, and re-connect.........all good so far.....   I should have started there first,but couldn't get to it myself............might be a good place to start !
Certainly alot cheaper than looking at the alarm/immobiliser to start with.

Grahame says the the engine is turning over 'as it should' so I cannot see it being a starter motor or ign switch problem. As it is a plain key then the ECU is probably the same or similar to mine - no built in immobilser.

According to the Pug handbook, the fuse for the 'Electronic injection' is No 18 and is 30 amp.

Do you not have one of these books Grahame? Says 'BOXER, handbook, operation and maintenance' on the front with a picture of a Boxer van beneath.

Frank

Hi,
If the built in immobiliser was not fitted to your age of van as Frank says then that is good news, good luck with the alarm removal,
Chris

Thanks Logburner, Frank and Chris for your input, much appreciated. 

No Frank, I don't have a Boxer handbook - wish I had, it might alleviate some of my probs. As I've mentioned elsewhere, I have just about everything on the habitation side of the van, including the original AS Harmony A4 user manual but nothing whatsoever on the base vehicle. Any idea where I can get hold of one?

As far as the alarm is concerned, I've decided to get it professionally removed. It will cost around £120 but at least then I'll know that it's not contributing to starting probs.

Once again, many, many thanks to all. Regards Grahame

Frank. I forgot to ask for the location of the Electronic Ignition 30 Amp fuse?

Regards Grahame

Grahame T wrote:No Frank, I don't have a Boxer handbook - wish I had, it might alleviate some of my probs. As I've mentioned elsewhere, I have just about everything on the habitation side of the van, including the original AS Harmony A4 user manual but nothing whatsoever on the base vehicle. Any idea where I can get hold of one?

They come up on ebay from time to time, don't pay a silly price for one though. There's one on there now but its from Poland and is in French.

If there is any particular info you are looking for then I could scan a couple of pages for you, but bear in mind that mine is a year older than yours.

Frank

Thanks for that Frank, I'll keep my eye's open for one. In the meantime anything on the vehicle electrical side, particularly fuses would be appreciated. (I wouldn't think that the difference in age would matter, OR WOULD IT??)

Grahame

Is this OK for now? 18 is the green bottom right one. - do you know where the fusebox is?


There may be some differences but possibly only small ones?

Frank

That's great Frank, thanks. Is this an extract from the manual you mentioned - if so it's made me more determined to acquire one? 

Does it mention anything about the under bonnet fuses?

Regards Grahame

The underbonnet fusebox is an Auto-Sleeper fitment, not part of the base vehicle. AFAIK

Frank

Thanks Frank. I'll leave you in peace to a while and keep you informed of progress as and when.

Regards Grahame

Hi,
On my van the fuses were located in the bottom of the glovebox under a lift up cover, there was also a list of what did what cast into the cover, yours may be different,
Chris

Thank Chris. Mine appears to be similar, will check tomorrow. Note, note.

Grahame

Grahame, I have scanned my little book of words & pictures into a .pdf file. If you send me your email address by private message, I'll send it to you as an attachment. Not perfect but readable, praps be OK for you until you can source a proper one.

Frank

Just a thought - I also have a petrol Boxer - it's a 2000 model but as far as I know it will be the same as yours. It has the electronic key recognition. When you put the key in the ignition and turn the ignition on, a yellow key symbol comes on the dashboard. On mine this yellow light needs to go out before you continue to turn the key to engage the starter otherwise the engine turns over but won't start. Occasionally the yellow light doesn't go out and I have to take the key out and start again.

Rgds

Mikebro

Thanks for that Mike. Unfortunately mine only has the basic key and no yellow key symbol.

When I turn ignition on I hear a click from LHS bulkhead area. Haven't checked it out yet - too busy.
I've also checked fuse 18 as advised by Frank - OK.

Thanks for trying Mike. Regards Grahame