Ignition on no crank episode

colb

colb

Senior member
 Newport, South Wales UK, the home of Zedshed Cymru
Popped out this afternoon just up the road and back, stalled the car as I was backing it onto the drive when I got back and when turning the key to restart, no crank no click from the starter. Tried a few times but zilch. Popped the boot checked battery terminals all clean and tight. Popped the hood and checked starter connections all tight. Decided to give it a few taps with a hammer, didn't hear anything move within the starter motor but when I tried the key again, car started. I suspect the ignition switch is iffy so ordered a replacement from Quarry Motors and will change it when it arrives. If thats not it then maybe starter motor next on list. Car is a 2003 2.5 93k miles on her.
 
Stalled it, battery was / is fine, thinking back I had noticed it had sarted sounding a bit different a couple of times when I was starting the car, difficult to describe the difference I noticed but could well have been the ignition switch feed to the starter starting to play up. Did 150 miles in it earlier in the week and had no problems, running like a dream.
 
Had a further poke about, car started but repeated starting it failed to crank, a couple of hammer blows brought it back but failed again shortly after. Pulled ignition switch and checked the starter signal wire was getting 12v when key in start position, it was. Turned my attention to the starter motor terminals pulled them off and cleaned them, they were preety bright when comming off so don't think that was an issues. I did clean the ignition switch with electrical spray cleaner whilst it was out. Starter now totally dead so ordered a replacement which shouild be here by Tuesday, Car Parts for less was the best price. May well pull the old one out tomorrow if the weathers fine, already loosened the two retaining bolts then retigtened them just to see I could get on them. Managed with a torx ring spanner, just about enough room the get on to them without a struggle, did need a tap with a hammer to get them started, sprayed some WD40 on them before tightening them up to make it easier when I come to take it out for the replacement. Seems @ph001 was correct with his diagnosis, will confirm when the replacement gets fitted.
 
Couldn't leave it alone popped out again and pulled the duff starter motor in readiness for putting the replacement in due Tuesday.
Didn't have to strip down the air box to gain access, all doable as it is for disconnecting the wiring with the battery negative cable being disconnected first. Used a torx ring spanner to remove the securing bolts, just enough room to get on them, socket ratchet wouldn't fit in the space. Bench tested the starter and it's completly dead.
 

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Found a very good post on another forum with great pictures showing how to remove the starter motor, link here https://www.zpost.com/forums/showthread.php?t=359809
 
Replacement arrived late this afternoon via DHL, a day late, straight out and put it on the car, reconnected and started first time. Cleared all the codes that had appeared from disconnecting the battery, all cleared except an annoying thermal oil level sensor, replaced this some months ago so it will have to await the next oil change before trying another brand of sensor.
 

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The plus of owning a manual car is in emergency can always get the car rolling and pop the clutch to get it going.
 
Good diagnosis and fix :thumbsup:

My oil level sensor is a goner too but seeing as I suck my oil out I haven’t given myself the opportunity to get underneath the car to replace it. No biggie as I do a manual level check every week.
But I’m now wondering if it serves a dual purpose due to its’ nomenclature i.e. thermal oil level sensor.
Is it measuring oil temp for overheating too?
 
The thermal oil level sensor in the sump only measures the level of the oil, a separate sensor on the oil filter housing measures the oil tempreture.
 
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