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Thread: D2 2004 Auto TD5 - intermittent Starter issues

  1. #1
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    D2 2004 Auto TD5 - intermittent Starter issues

    Hi all, Im hoping someone can help with a trouble shooting approach to my problem. I'm not an auto elec though i have some tools and a multimeter with me while I'm travelling around Australia, sometimes it starts - sometimes it just clicks once (I assume its the starter motor that clicks). The battery reads 12.5 - when the ignition key is turned goes to 11.7 - when it starts goes to 14.2. The battery is nearly 2 years old and we travel 100+ klms per day on a new alternator. This starter motor has likely done 217000 klms. I've replaced the 30amp fusible link #13 with a spare I carry with no change in behaviour. Underneath the red cable on the starter motor is tight - the small spade connector is a bit grubby so I took on / off / on to reseat it. Is there any suggestions how I can pinpoint where the real problem is here. thanks heaps

  2. #2
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    My feeling is that your battery is just about dead. It might be worth getting it load tested.
    Cheers
    Slunnie


    ~ Discovery II Td5 ~ Discovery 3dr V8 ~ Series IIa 6cyl ute ~ Series II V8 ute ~

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    Hi, google out "td5 starter solenoid repoair kit" cos IMO that's what you need, they are cheap in UK but not so cheap Down Under TD5 Starter Motor Solenoid Repair Kit NAF500010KIT
    Discovery Td5 (2000), manual, tuned

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    I removed my starter & cracked it open. Then I took the plunger and points to a local place that sells such things. Can’t remember the name of the place, sorry. I think the repair cost me like $50 & was a super easy home repair. Except the top nut on the starter. You will need an extra wrist on your arm to reach it. I ended up using all my socket extensions with a swivel on the end and I attacked it from the top. It worked for me. No issues with the starter since.
    "Land Rover - making mechanics out of everyday motorists for nearly 70 years"

  5. #5
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    Yeah, check battery first but it is most likely a case of needing new solenoid contacts.

    I’ve got same issue. Haven’t replaced contacts yet because just cleaning all the carbon out when I was diagnosing it gave me another 12 months of use. I like living on the edge.

    People also claim a well placed broom handle and mallet tapping the starter motor body can shuffle things internally enough to get a start instead of a click. I assume this vibrates the carbon dust off the contact briefly.

  6. #6
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    Thanks. Yes this morning needed a small tap on the starter to fire a start out of the old girl... will get prognosis tomorrow though based on popular theory I agree the solenoid points are on final stages.

  7. #7
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    I’ve had this in my watch list on eBay for a while. Seller is Sydney based but I have had no dealings with them. Looks like what we both need.

    For Land Rover Discovery Defender TD5 2.5 Diesel Starter Motor Repair Fix Tool 654936527829 | eBay

  8. #8
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    I reckon you’re on the money. Being on the road with a schedule will probably mean a stop gap repair till I’m home in April rather than waiting for goods to ship unfortunately. See how we go with the auto elec tomorrow D2 2004 Auto TD5 - intermittent Starter issuesD2 2004 Auto TD5 - intermittent Starter issues

  9. #9
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    Quote Originally Posted by ahw3617 View Post
    Being on the road with a schedule will probably mean a stop gap repair till I’m home in April ...
    Solenoid is your problem, a clean out should get it working well enough to get you going for a few months.

    If you need to "tap" the starter, try the solenoid, not the starter body and if you do it while trying to start the motor, you should get more success.

  10. #10
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    Quote Originally Posted by ahw3617 View Post
    .... The battery reads 12.5 - when the ignition key is turned goes to 11.7 - when it starts goes to 14.2. The battery is nearly 2 years old and we travel 100+ klms per day on a new alternator .....
    Battery doesn't sound too bad, but check something else.
    Because you have a TD5, when you first click key to ign on(with dash lights all on), your 11.5v reading sounds about right. With ign on and not starting, you have a very high powered fuel pump running, and possibly the glow plugs too.
    Not 100% sure if the glow plugs are on/off depending on engine temp, but at some point they're going to be on.

    So do a check where you have ign on for at least 30sec. You should hear the fuel pump running. If you do hear it, then watch the volt meter. Glow plugs don't run for too long .. maybe 10sec or so, but they are a big draw on the battery too.
    So a quick and dirty battery test: ign on, watch volt meter, listen for fuel pump whirring. when it stops whirring, what is the volt reading now(before you start it up)..

    I have an old 300 Tdi, and overnight my battery seems to rest at 12.4 - 12.5v(in warm weather) .. less if cold(~10°C or less).
    Ign on, the glow plugs will drop the 12.4v down to low 11's .. in warmer weather maybe high 11's. I can't say that I've ever seen the exact same reading in succession.
    So I wait 10sec or so glow plug relay clicks off, volts recover to about 12.3.
    Battery is now 11 months old or so now .. showed much higher voltages(like 12.7 when new over night) and high 11's with glow plugs doing their stuff. The other values are with a now nearly a year old battery.
    The battery was replaced under warranty, and the old one showed really bad values under load. Would show 12.3-12.4v over night, but with glow plugs active, would dip down to the mid 10 volt range.
    If I hadn't started the Tdi for 2 days tho.. it's show under 10v with the glow plugs active.

    What you describe sounds a lot like Sierraferry said ... most likely solenoid(or that spade wire still hasn't seated perfectly.
    Brother had this issue crop up on a recent trip to the Vic high country. first time were were on a very steep track, and he parked it up after he got a bit stuck. I came past him and parked on a more level area and walked down to him. He went to start it, and just got clicks.
    I just thought it was the hot conditions, so sprayed some water out of a drink bottle, but had to get back under and whack it while he tried to start it.
    Like JimDAUS said, hit the solenoid body, not the larger motor body.
    Caused us a bit of grief every now and then for the rest of the 5 days, but not overly major.
    When he got home, he replaced the starter too(like JohnD2 said) .. he called me and said either he got really lucky, as it came out quite easily after I warned him that the top bolt was supposedly very hard to get too.
    Arthur.

    '99 D1 300Tdi Auto
    '03 D2 Td5 Auto

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