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Starter motor failure ?

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Re: Starter motor failure ?

Postby knobby1 » Fri Dec 23, 2016 8:24 am

Retired John wrote:good when key is in start position so fault appears to be between key and main fuse box , tomorrow I will attempt to dismantle the ignition and remove the unit itself any easy ways or clues ? the only manual I have is a useless haynes one best used as a doorstop :oops:


The ignition switch just clips on the back of the key barrel, 10 minute job...

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Re: Starter motor failure ?

Postby Retired John » Mon Dec 26, 2016 10:57 pm

Well Knobby I have pulled all the bits out now and same old same old just a clunk so redid the test to make sure the relay was not the problem did a direct touch from the live block beside the main fuse box to terminal 5 on the starter relay and bingo starter fired up BUT I also did a "lucas" and made smoke in fact the thin wire from the fuse box to the main live block caught fire and burnt through :oops: :( think I am now in deep doos , later I will disconnect power and pull the fuse box and attempt to find out wtf has happened seems no fuses have blown which is strange , Any Ideas ? :?
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Re: Starter motor failure ?

Postby Retired John » Wed Dec 28, 2016 9:09 am

After much testing and more reading of posts here in technical I saw a couple that mentioned faulty glow plug relay/wiring/plugs so pulled the R2 relay and bingo no smoke no drama and starts every time ,,,, so far :? but although glow plugs are dispensable with our climate the A/C is now a non event even the fan itself has no power seems they share the same relay so not sure where to from here :? the wire that burnt out goes from under the main fuse block and joins in to the main + inlet and jumpstart block beside the fuse box , I have not reconnected it as It is I am guessing the glow plug feed ?
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Re: Starter motor failure ?

Postby dirtydog » Wed Dec 28, 2016 9:34 am

Retired John wrote:Well Knobby I have pulled all the bits out now and same old same old just a clunk so redid the test to make sure the relay was not the problem did a direct touch from the live block beside the main fuse box to terminal 5 on the starter relay and bingo starter fired up BUT I also did a "lucas" and made smoke in fact the thin wire from the fuse box to the main live block caught fire and burnt through :oops: :( think I am now in deep doos , later I will disconnect power and pull the fuse box and attempt to find out wtf has happened seems no fuses have blown which is strange , Any Ideas ? :?



Sounds like the fused link on the mk6, mine did the same. Was down to a bad earth on mine, what I did to test was connect a jump lead from the battery neg terminal to the starter body and it started every time.
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Re: Starter motor failure ?

Postby Retired John » Wed Dec 28, 2016 9:52 am

OK silly question where do I find this fused link please ?
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Re: Starter motor failure ?

Postby dirtydog » Wed Dec 28, 2016 10:19 am

That's what went up in smoke, it's just a wire that runs from the jump point to the relay that's used instead of a fuse



Here's the thread about mine, sounds very similar to your problem. I did the same, new starter, new battery, new ignition switch and cleaned earth points when I fitted the new starter and battery. It was the earth in the end

viewtopic.php?f=5&t=160488
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Re: Starter motor failure ?

Postby Retired John » Wed Dec 28, 2016 10:55 am

Ok thats cool but when I reconnect that wire and switch on the ignition it smokes and refuses to start when the glow plug relay is in situ take the glow plug relay out and the truck starts and runs ? I have left the wire disconnected for this reason is it necessary ? would it be better to put a decent resetting relay in that line ?
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Re: Starter motor failure ?

Postby ned » Wed Dec 28, 2016 11:12 am

My glow plug fuse link wire burnt out 3 years ago and other than in -0 and below it starts fine. N
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Re: Starter motor failure ?

Postby knobby1 » Wed Dec 28, 2016 7:37 pm

Retired John wrote:Ok thats cool but when I reconnect that wire and switch on the ignition it smokes and refuses to start when the glow plug relay is in situ take the glow plug relay out and the truck starts and runs ? I have left the wire disconnected for this reason is it necessary ? would it be better to put a decent resetting relay in that line ?


Sounds like one or more of your glow-plugs has gone on the fritz....as mentioned by some, they aren't a real necessity in our climate. The air-con issue is a bit strange though..!

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When I die, I want to go peacefully in my sleep like my Grandfather, not screaming like the passengers in his car..!
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Re: Starter motor failure ?

Postby Retired John » Wed Dec 28, 2016 7:43 pm

knobby1 wrote:
Retired John wrote:Ok thats cool but when I reconnect that wire and switch on the ignition it smokes and refuses to start when the glow plug relay is in situ take the glow plug relay out and the truck starts and runs ? I have left the wire disconnected for this reason is it necessary ? would it be better to put a decent resetting relay in that line ?


Sounds like one or more of your glow-plugs has gone on the fritz....as mentioned by some, they aren't a real necessity in our climate. The air-con issue is a bit strange though..!

Lord Knobrot

The a/c fan etc runs off the same relay Knobby R2
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Re: Starter motor failure ?

Postby knobby1 » Wed Dec 28, 2016 8:37 pm

Retired John wrote:
knobby1 wrote:
Retired John wrote:Ok thats cool but when I reconnect that wire and switch on the ignition it smokes and refuses to start when the glow plug relay is in situ take the glow plug relay out and the truck starts and runs ? I have left the wire disconnected for this reason is it necessary ? would it be better to put a decent resetting relay in that line ?


Sounds like one or more of your glow-plugs has gone on the fritz....as mentioned by some, they aren't a real necessity in our climate. The air-con issue is a bit strange though..!

Lord Knobrot

The a/c fan etc runs off the same relay Knobby R2


Ah...fairynuff...I suspect you've left the fusible link out/disconnected and refitted the relay and seen what happens.??

Lord Knobrot
2008 2.4L RWD 170+PS 6-speed 350 LWB High Roof.

When I die, I want to go peacefully in my sleep like my Grandfather, not screaming like the passengers in his car..!
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Re: Starter motor failure ?

Postby Altransit » Wed Dec 28, 2016 9:02 pm

I cut out and taped up that wire on mine, and left the relay in situ, and it has started and worked fine ever since. You definitely won't ever need the glow plugs over there in the land of Oz :D :P
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Re: Starter motor failure ?

Postby Retired John » Wed Dec 28, 2016 10:02 pm

knobby1 wrote:
Ah...fairynuff...I suspect you've left the fusible link out/disconnected and refitted the relay and seen what happens.??

Lord Knobrot

Just done that and there is a sizzling noise from somewhere under the main fuse box when the key is on :oops: so pulled it quickly :lol: no more sizzle , also did a full check of accs have lights H/L but no indicators no dash lights no a/c radio works gauges work . I am thinking just leave it parked till my local auto elec gets back from Christmas break , at least it is running so I can drive it to his shop :roll:
So IF the burnt wire is the fusible link which is the glow plug wire to cut to take them out of the circuit Btw ?
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Re: Starter motor failure ?

Postby knobby1 » Wed Dec 28, 2016 10:15 pm

Retired John wrote:
knobby1 wrote:
Ah...fairynuff...I suspect you've left the fusible link out/disconnected and refitted the relay and seen what happens.??

Lord Knobrot

Just done that and there is a sizzling noise from somewhere under the main fuse box when the key is on :oops: so pulled it quickly :lol: no more sizzle , also did a full check of accs have lights H/L but no indicators no dash lights no a/c radio works gauges work . I am thinking just leave it parked till my local auto elec gets back from Christmas break , at least it is running so I can drive it to his shop :roll:
So IF the burnt wire is the fusible link which is the glow plug wire to cut to take them out of the circuit Btw ?


Just do what Altransit did and you should be good...I'd be popping the main engine bay fuse box cover off and having a bit of a bo-peep in there just to make sure nothing untoward is happening.

Lord Knobrot
2008 2.4L RWD 170+PS 6-speed 350 LWB High Roof.

When I die, I want to go peacefully in my sleep like my Grandfather, not screaming like the passengers in his car..!
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Re: Starter motor failure ?

Postby Altransit » Wed Dec 28, 2016 10:21 pm

The relay itself may be fried :idea: Once the fusible link is cut it shouldn't be passing any current. Check the relay bases in the fuse box for heat damage :idea:
1994 Mk4 SWB 115 Minibus 70ps Di (R.I.P.)
1997 Mk5 SWB 115 Minibus 70ps Di (Gone, but not forgotten!)
2004 Mk6 SWB T280 Medium Roof 85PS 2.0 TDDi - Vantunered (Also gone)
2008 Mk7 SWB T280 Medium Roof 85PS 2.2 TDCi - Also Vantunered
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