Auto start - and keep starting

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adrian hollister

adrian hollister

Active Member
Posts
132
Location
Bodmin Moor
Just done a good (so I think!) rebuild of the engine - new head, pistons, big end and most of the pipe work and sensors. Anyway, all started ok and run's very very nicely now - the power is stunning. I do have one little problem though... after about 30 mins of running I can hear the starter kick in whilst it's running. I immediately stopped the engine and tried to restart, but in ignition switch position II the enginge auto starts and the starter keeps running.

I've pulled the starter relay out and checked the ignition switch with a multimeter, all appear to be ok. Everything is fine when the engine is cool. Am I going mad here or does anyone have any suggestions where to check next?
 
it could be the solonoid sticking on the starter motor or try checking the connections to starter motor making sure the thick wire from the battery to starter is not touching the thin wire that goes onto the starter as this will short and cause the starter to spin over without ignition.
 
Checked and everything seems ok and I can follow both wires back to the loom without nicks or getting a shock myself :) . I'm gonna try to take the ignition switch apart to see if there is something wrong in there. Looks like a sealed unit (the black switch at the back of the steering lock barrel) - anyone done this before? I don't want to break it as they are 80 quid of fleabay!
 
You cannot get a shock from a 12 volt system.

Sounds like the starter solenoid wire on the IGN switch may be attached to the wrong tag. Check carefully which tag it should be on.


But I agree with ColinL that a prime suspect is right at the starter motor itself.

Read what he said there. If the BIG cable is anywhere near the small one that fires up the solenoid, make some space between them.

Be SURE to disconnect the battery FIRST as the big black cable is always LIVE to the battery and without a fuse. If you short it with a spanner you'll get a fright and burned too.

NEVER EVER work on electrics in a car with a ring on a finger.

But as you don't say which variant of Disco it is no-one can help more than that.

Has the starter motor and pinion and the ring gear survived this experience?

CharlesY

CharlesY
 
It's a 300TDI. Everything still starts and initially I thought this was a one off thing... as when the engine is cold it starts fine only engaging the starter motor when the key is in position III. However, once the engine is running and hot you can hear the starter kick in. Once it's hot the starter operates when the key is in switch position II or III - let it go cold again and it starts as you would expect. I've no idea what I'd do if I was trying to drive it like this but I'm guessing it would not be good.

The cables to the starter seem fine to me. I'm also checking back through the areas touched by the rebuild to see if I've pinched a wire.
 
adrian hollister said:
It's a 300TDI. Everything still starts and initially I thought this was a one off thing... as when the engine is cold it starts fine only engaging the starter motor when the key is in position III. However, once the engine is running and hot you can hear the starter kick in. Once it's hot the starter operates when the key is in switch position II or III - let it go cold again and it starts as you would expect. I've no idea what I'd do if I was trying to drive it like this but I'm guessing it would not be good.

The cables to the starter seem fine to me. I'm also checking back through the areas touched by the rebuild to see if I've pinched a wire.
Click to expand...



IF you need a new ignition switch they are £29+vat from these people:

STC1435 Steering Column Lock and Ignition Switch Assembly - from MA081992 (except Japan)

I bought one from them for our previous TDi200 and loads of problems were resolved at a stroke !!!

Dead easy to do as there is a plug connector on one end and a plug and grubscrew arrangement on the other - takes two mins to change over with no changing of keys neccesary !!

Good luck

Dave

PS The more I read your last post the more convinced I am that it's an ignition switch problem - however It's only £30 to eliminate it !!
 
Last edited:
Took the switch apart tonight (not as difficult as I thought it would be) and everything in there is fine. Nothing broken, no worn contacts and no corrosion either - a perfect switch. This means the problem is somewhere else. Is the solenoid on the starter a replaceable item or is it a whole new starter motor? and does anyone have a good cheap source for the relays?
 
you can buy the solonoids seperately but for the price of a new one you may be able to buy a good used starter. you need to find somewhere near you who sells reconditioned units so they can supply you with the solonoid, the last one i bought cost me £25 from AUTOFAX in ashton-under-lyne. if you are close by the phone number is 0161-344-0275
 
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