Thread: Confirmation of our diagnoses ????

Hi all
The 2002 TD5 wont start in the mornings? So Jump start with 2nd battery. First attempts at jump starting just gave same clicks as main battery did, after 6 or 7 attempts engine fires up as normal. I assumed main battery was crook so purchased a new one. At first it was fine but after a few hours same symptoms.

First 4 or 5 attempts result in a click and nothing then She fires up fine on the 7th attempt.

After discussing this with Kyle (Alien D2) Kyle is leaning towards a crook solenoid on the starter.

After checking the volts, terminals and getting the same from both batteries even with a second one hooked up as a jump start I get the same result.

Both batteries are sitting on 12.9 volts.

Engine running gives 13.7 volts.

Fuel pressure reg was done about 6 months ago and fuel was leaking onto starter. No leaks since.

Brake lights are working.

So I will go get a kit and fix Solenoid unless anyone has any thing else to add ?????

Hi All
Job done, Took about 5 mins to undo the 2 lower bolts & the terminals. Took about 4 hours to get the nut on top off!! It was an absolute pain, Used every 3/8 extension & Universal drive I had in every possible combination. Had to be very careful to not round the nut, Getting a good purchase on the nut with a uni joint is very difficult.

As mentioned in previous threads do not attempt this with a 12 sided 15 mm socket, use a good quality 6 sided socket. The nut was so tight you risk rounding it and I would hate to think how it could be removed once that occurred??

Eventually it came loose, and starter removed. Quick trip to the local Auto Elec who charged me $30.00 to replace the insides of the solenoid & bench test the starter. I would have been capable of doing it but by now had had more than enough of British engineering.

The solenoid was dry inside, no oil or fuel present, It just failed due to 10 years of use. Any one planning a long trip with a vehicle of this age would be well advised to get the repair kit and throw in in the glove box. I found the kit from $8.00 to just under $30.00 in various places. But I think if you have a good Auto elec the bits would be even cheaper.

The actual repair was really easy (once the difficult nut is removed).

Wonder what this would have cost at one of the dealers???