1.6TD will not turn over/start (1987 Joker)

[davejl]

I've had a long term problem with battery discharge, normally after 2 weeks or more so to prevent this I've kept the van plugged in to keep the batteries 'on charge'. The not starting has been exsaperated since I fitted a USB charger(wired with the radio to the leasiure battery). Already planning to change split charge relay for Lucas SRB63 (have previously changed the relay).

Whilst the van was in for MOT a couple of jobs last week they had trouble starting; similar when I went to drive last Saturday having ink been returned from the garage and plugged in overnight I needed to jump start of the car and then again when out and about despite a good 45 minute drive. The vehicle battery is only about a year old!

I've previously checked the alternator (65A) output have changed the brushes I confident that ok; similarly when plugged in there is over 14V at both batteries are charging ok. Battery is a Bosch 72Ah that was changed in March 2014

Other things that I've checked using the wiki:
Main battery volts is 12.95; leisure is 13.14
Potential Battery discharged (measured by disconnecting -ve and measuring between battery terminal with multimeter) zero mA
Earthing straps and cables all checked visually and for continuity (all seem ok)
On turning the key (good bright lights on dash including glow plugs); lights dim and engine will not turn. Battery volts drop to around 10 - shows current draw and go back up to near original when key released.
Have checked glow plug fuse/wiring - is ok
Can here relay energised in black box in engine bay

So after all that thought it might be starter solenoid; so changed starter motor for new one from brickwerks. Still won't start so now I'm scratching my head!?

Any thoughts?

[marlinowner]

Try a different battery.

[Oldiebut goodie]

All I can say is the checking of the earthing visually is no substitute for physically removing each and every connection and cleaning well. Same goes for continuity check - just because a miniscule current (minuscule if you don't accept the former word) from a multimeter passes it doesn't mean that high current will pass as easily.

[davejl]

Thanks, I'll try those... lets see how I get on

[MidLifeCrisis]

Potential Battery discharged (measured by disconnecting -ve and measuring between battery terminal with multimeter) zero mA

Confused? In the above quote - are you measuring the current between the disconnected ground strap and the negative battery terminal? (Or are you measuring the current between the positive and negative battery terminals)

*edited to remove question already answered

[MidLifeCrisis]

Sorry - going to reinstate my original question (I thought you'd answered it in your original post but now I'm not so sure)

What is the voltage at the battery when the engine is running ?

[davejl]

Midlife - yes measuring between disconnected earthing -ve cable and -ve terminal.

can't measure voltage at battery when engine running (as it won't start) - however when done before it was 'healthy' something like 13.65-13.95 springs to mind!

[MidLifeCrisis]

Ok - so no obvious current drain and the alternator appears to be charging but the battery goes flat when the van is left idle?
Other than not starting is there any other indication that's the battery is flat?? Voltage level?

You also mention that the problem got worse when you added a USB charger to the leisure battery - which obviously doesn't make sense ........ unless your split charge relay is jamming on when the engine isn't running and the sub charger/radio etc is draining the main???

But it is weird?!?!

[davejl]

That's why I'm scratching my head; still have a few things to check like ignition switch, earths etc

Battery voltage all good (charged via mains an BBB); have got new split charge relay as recommended in the wiki - let's see what happens this weekend

[MidLifeCrisis]

Think I'd be tempted to pull the split relay out and see if that 'fixes' it!!!

[davejl]

Right Update on the progress over the last 2 weekends...

Thanks for all the advice

Changed starter no real change but decided to keep it fitted.
Next was ignition switch and split charge relay (SRB630), also decided to 'upgrade' cabling between battery and engine, battery and started and alternator and battery (parts from AES) and change earth on front of gearbox.
Also found the USB socket and radio memory feed were not wired to leisure battery as I thought (main stereo feed is) - so changed that.
Change glow plug fuse (not broken but in poor condition)

Had to replace vacuum pump as it got 'damaged' when doing the starter change!

It starts & better than before!

Got see whether it will hold charge now; if not i think it will a new battery.