Starter Problems

[timj]

Hi I have a 2006 1.6 petrol 206cc. When I turn the key I just hear a load click and the engine does not turn over. I had a call out with the AA, he diagnosed a new starter motor. I bought a 2nd hand tested starter and fitted it (I have also tested it and it works fine as does the original). Same problem, no start. The ignition key is working fine, battery is 12 months old and reads 12.9v. There is a constant 12.9v at the starter terminal and when the key is turned to start position the solenoid terminal reads 9.7v. Can anyone help please.
Thanks Tim

[IanL]

The loud click suggests that the starter pinion is engaging in the flywheel, but the switch within it which puts current to the windings when the pinion has engaged is not doing so.

There are two possible causes - either both starters are defective, or the pinion is not fully engaging because of damage to the flywheel. Try moving the car in gear, or take the plugs out and turn the engine over say a quarter turn of the crankshaft. This will give the pinion a different portion of the flywheel to engage with. If it then works, it is a fair bet the problem is damaged teeth on the flywheel.

[Slo]

Wiring and probably bad earth leads. Particularly copper wire that has gone black due to being burnt from high current which is caused by running the starter motor a lot over time and the elements doing the rest.

[timj]

Thank you. The wiring all looks clean and solid. I'm inclined towards both starters being faulty. I did test them both off the car and both seemed to work okay. However that isn't under load!! Also I was expecting the solenoid terminal to be at 12.9v also??

[IanL]

Slo's point does tie in with the low voltage on the solenoid (except bad earths - they could not affect that). Assuming you mean the connection to the solenoid operating coil, not the contactor, you could try applying +12V directly to that point, to see if it makes a difference. There is nothing in the SEDRE to explain why the voltage should drop like that, so it could be a poor connection in the BSI, the ignition switch, the engine compartment fusebox or the wiring between those.

[timj]

I'm going to do just that and see what happens. I haven't traced the solenoid wire back to the ignition switch, can you remember by any chance what route it takes etc. I've seen the Haynes wiring diagram but that just shows a direct connection!! Won't get to the vehicle until Saturday now. Thanks again

[Capncol]

Sounds like a duff battwry

[IanL]

The SEDRE shows the wiring from Battery+ via MF7 in the engine compartment fusebox to the key unit, then back to the fusebox and then to the solenoid. (I was wrong about the BSI being involved) You could disconnect the battery+ and the solenoid, get a helper to operate the key to start and measure the resistance through the circuit. If that's ok, it does begin to cast suspicion at the battery. However, if it is the circuit at high resistance, you could just become highly fashionable and fit a pushbutton.

[gazza82]

Sounds like a duff battwry

Doesn't take long for them to calcify if the car has been sitting around unused for a few months.

[timj]

Well there's a few things to try out this weekend thanks. I like the push button start just depends if the better half will go for it lol.

[IanL]

Just had a better idea: Without disconnecting anything, put the voltmeter between Battery+ and the starter solenoid, and observe the reading when the starter is operated. If it shows nearly zero, there is nowt wrong with the wiring (it is not dropping much voltage), but if it shows in the region of three volts, the converse is the case.

[GrandadMonkey]

When the battery was replaced was the correct one used? The one for the 206cc is taller than the one for the hatchback. If someone has tried to economise by buying the shorter one then you will have connectivity problems because of the strain on the terminals. It MUST be 190mm tall, not 175mm.

The shorter battery can give the symptoms you describe. Please check the height.

If the battery is fine and correct then it points to a brand new starter motor being required - common with cars of 2004-2006.