Since buying the car the starter has been a little sporadic. Most of the time it was fine but occasionally I would just get a solenoid 'click'. A second (or third) attempt would usually resolve the issue. Naturally I assumed a sticky solenoid was the problem and was planning on either stripping and reconditioning or replacing the starter at some point.
Whilst working on the inlet side to replace all the hoses, paint the block and clean the LH engine bay I realised that getting to the starter is quite a lot of work, much of which I had done already. So, I decided to splash out on a shiny new starter today. I removed the old one (that top bolt is an interesting challenge) and swapped it for a new item. However, now I have nothing... If I short the solenoid connection on the starter the engine cranks fine. Operating the key seems to fire up everything apart from the starter as when I move it from ignition to start I can hear a number of noises (relays? Injection?) but no solenoid and no starter, not even the solenoid click I used to get when it did not start straight away.
I should point out that as part of the current work, I have removed the plenum and expansion tank, removed the engine loom plug from the fuse box which I then unbolted and lifted out of the way, holding it up with a bungee whilst I cleaned underneath and around it. I have also removed the air box (disconnecting the MAF) together with plenum, to blast and repaint them before refitting, All this causes me an issue; normally I would only do 1 job at a time as it is more easy to identify if/when problems may have been introduced. Now I cannot be sure if the issue is the wiring loom, fusebox , something else I have done or simply the original problem getting worse....
Here is what I have checked so far:
- The Blk/Yel wire from the fuse box plug to the solenoid = good connectivity.
Soldered a new female spade connector onto the solenoid wire.
Cleaned all the fusebox engine bay plug and socket connections.
Cleaned up the heavy starter 'from battery' and 'to car' ring terminals and fitted shiny new nut and spring washer.
Cleaned the MAF plug and socket. I know, I know.. at this point (and the next) I was clearly showing desperation.
Cleaned and tested all the fusebox fuses and relay connections / operations.
However, I cannot help thinking I am missing something obvious here. The starter was mostly operational from the key before I stated the current work. what could I be missing? Have I unplugged or disturbed a connection somewhere?
Any help or suggestions gratefully received.
Ian