Fault finding a faulty 300tdi starter

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Originally Posted by workingonit

Advice I've read is not to tap the starter body as there is a risk of loosening the magnets glued to the inside. Not sure if enough shock can transmit to the starter body if you are tapping the solenoid body.

Have several D1 Tdi300's. One vehicle had issues with the earth strap running from the bell housing to chassis - refresh the metal contacts. The second vehicle had an issue with the solenoid, not serviceable, which is annoying as my old Toyota solenoid is serviceable with the purchase of new contacts for a few dollars. The starter can be taken apart and the thrust components cleaned/lubed.

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Unfortunately when the vehicle is not moving I've no option but to tap until I have more time to get in there properly. Good advice nonetheless.

Will check earth strap.

Pulling apart starter is further down the list but good to know it's an option.

Cheers

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Originally Posted by trumpycam

Had similar problem in my 81 RRC with 300tdi. Frustrated for nearly 12 mths, would be no problem for months then without warming would fail to start, but would start after a short time, seemed worse on hot days. Went through all possibilities relay starter etc.Problem ended up being the small wire to starter, ran a new one direct from relay to solinoid problem solved. Ended up costing a fair bit for a piece of wire and 2 connectors. Ended up with a lot of spare parts.

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Yes will definitely check the wire out. Also check the relay while i'm on it. Cheers

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Originally Posted by rrturboD

Starter solenoid is rebuildable....
Had a recent experience if intermittent starting, and sometimes staying on.
removed solenoid and polished sleeve and piston. All contacts etc were ok.
Now runs every time and shuts off when expected.

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Be interesting to know your brand. Mine are Bosch. I can pull the piston and clean the cylinder. But the contacts are enclosed inside a can that is crimped to non conductive plastic - you can't inspect or renew the contacts unless you risk destroying the enclosure. The old Toyota unit allowed you to access the contacts by undoing some small bolts that hold the can and its o-ring seal to the plastic body.

Think it was Bosch ... the piston had a scratch on it and the edges were slightly raised, hence the polishing. Contacts were a visual inspection, no heavy corrosion etc.

Did I miss it or has nobody mentioned the brushes?

Almost always they wear down and not enough pressure on the armature and a tap lets them move and contact better.

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Originally Posted by johnp38

Did I miss it or has nobody mentioned the brushes?

Almost always they wear down and not enough pressure on the armature and a tap lets them move and contact better.

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Could be that John. I'm going to pull the whole starter off and report back. Cheers

I had a similar problem in my D1 300 tdi. Started off only on really hot days about once a year.

I would remove turbo hose and start it with a screw driver across solenoid.

As time went on (a few years) it started to become more frequent. So what I did was piggy backed the small wire to the starter solenoid.

I then ran the wire to near the battery with the end taped up. When it would not crank, I could then lift the bonnet and place wire on positive battery.

This also eliminated the starter motor/solenoid as being the problem.

Over time it got worse, to the point it was like yours, about one in ten it would not crank.

I just recently ran this wire to a starter button, which has solved my problem.

​Hi all,

Thanks again for the comments and suggestions.

As a first measure I decided to pull off all the cables with the starter still in place and give everything a clean. The cables and nuts were spotless but I gave them a wire brushing anyway and put it all back together.

It has started without fail every time since (dozens of times).

I suspect the small white wire with the spade terminal might be the culprit. Maybe it wasn't sitting correctly or it has a bad solder and the act of pulling it off and on again was enough to settle it.

The love taps were probably just enough to make the connection too, hence why it would start most times after a tap.

Ot it could be nothing to do with the terminal and something else altogether!

Anyway, goes to show that the simplest approach is often the best to begin with.

Dave