D1 96 300TDi Auto - Not Starting (intermittently)

Quote:

Originally Posted by mattg

We got it all fixed with a relay on the switch wire.

Seems to have a challenge on the park sensor now with it needing to be taken out of park and back in again before it will start. Any tips on fixing this?

Your starting problem sound like a couple of intermittent faults occurring together or singularly.

The lights disappearing while using the ignition switch, - dodgy ignition switch contacts, replacing ignition switch is the only real cure here.

Getting out of the car and back in again, or moving auto selector then car starts - check switch on auto selector but first check the connections are tight and the connectors that go onto that switch are crimped tight onto their wires as well, ( a bit of bother getting to the switch under all the trim ).
No power at all intermittently, a loose joint some where in the current path from and to the starter motor, - check for a faulty earth path by turning head lights on while turning engine over if no noise and the headlights disappear completely, look for a faulty joint in that earth path;

For the earthing, start at the earth cable clamp on the battery, check clamp for any corrosion, good solid cable crimp, clean and tighten onto post.
Follow earth cable down behind battery to the first earth to body lug should be soldered on solid look for any cracks in the solder, and the lug to the body should be bright metal.
Again follow the cable from the body lug to the end of that cable where it meets the chassis, look at the end lug for a tight crimp end and solder if necessary, the lug should have a clean metal to metal contact where it is bolted to the chassis.

Go to the other side of the engine bay and look behind the starter motor for the earth strap that goes between the bell housing and the chassis. Check both ends for clean bright metal to metal contact, I have found lots of these joints only relying on the bolt for electrical contact as the chassis was still painted, clean the paint and any corrosion away then smear a bit of grease or Vaseline around and over the tightened joint to stop moisture wicking it's way under the joint.

To do all that work should take just under a hour, I will be interested to know what you find after you finish the cleaning all of those earth path joints.
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