Club 80-90 Forums

Hi all, hoping for some ideas. For some time, had intermittent problem when you turn key to start van, nothing happens. Normally righted itself but got worse so, as I suspected the solenoid, replaced starter motor and solenoid (which broke apart on dismantling) with a new one from Alan Schofield. All fine at home, started easily and quickly.
Yesterday, half way to Devon, stopped in Asda for supplies and nothing. Managed a push start and now parked in hill on campsite in Devon!
Battery fine, I think earths are fine. Lights come on on dash but not even a click when try to start (though it may work fine when I next try it, haven’t tried today). Any ideas? Is there a starter relay in fuse box? Could that be at fault?

There is no relay
the trigger wire from the ignition switch runs to the relayplate/fuseboard, thence to the engine bay, thence to the starter solenoid
check the wire hasn't come off the starter solenoid, it should have a latching terminal and wire should be cable tied to solenoid to stop it vibrating loose
If you carry a spare ignition switch electrical contact plate then you can test the wiring with that, it isn't uncommon for the electrical contact plate to fail over time the nylon gets worn by the metal tag from the key barrel and may not move enough to make contact

everyone should carry one of these


part number 111 905 865 L, available readily everywhere, Ebay, Amazon, your usual T3 specialist parts supplier of choice

Thanks Aidan, will look at that if I can work out how the ignition switch comes apart. Hope I can do a temporary fix until I next get home!
Incidentally, you reconditioned my gearbox quite a few years ago now - still going strong Thanks again for that

Another common intermittent starting problem is caused by the trigger wire corroding and thus raising its resistance and lowering the volts available for the starter solenoid. The end of the trigger wire is quite exposed and probably quite old. Cut back and replace, if crusty and green inside the insulation.

Thanks for that, yeah did try and clean corrosion off but just been underneath and connector not the tightest. Thought I’d tightened it properly! Can’t get at it enough to replace the connector but when it stops raining I’ll nip the connector tighter.
Have also ordered ignition switch to get here Monday. Good job there’s plenty if walks from the campsite!

Still need help! Dry day today so took the engine cover off and I find that when the key is turned, I do get a click at the solenoid/starter and also from a black box on the left back of engine bay (looking from front). This seems to have some sort of relay in (12v 40 amp).
So it seems unlikely to be the ignition switch that’s causing the problem.
I cleaned the connector going to the solenoid and tightened the connector so it makes better contact. I also took the earth off the body that connects to the starter motor and cleaned all contact points to ensure a good earth. Tried to start the van, hesitated at first but after a second, it started. Started several times since but as it’s followed this pattern before, I don’t feel confident I’ve cured the problem. Don’t want to drive to a busy location, no hill and it won’t start!
Any more ideas?

have you had the battery terminal connections off and back on ? just wondering if you have a poor contact there - is the battery clamped properly or can it move about a bit ? I'm guessing you are 2.1 petrol, I don't think you said

It’s a 1.9 petrol. And yes I have had battery terminals off and yesterday emeried connectors and posts. Maybe that has helped. Started again this morning but that doesn’t tell me much! I will check the body connection for the battery earth later in case that’s iffy. But not sure what that relay (?) in the black box at the back does? Is it for some other part of the electrical system?

The relay in the black box is for the manifold heater , nothing to do with your starter not spinning
You can connect the spare replacement ignition switch by simply unplugging the old one and plugging the new one in without fitting it as a temp test

Thanks for that. Really useful suggestion. Have now got the switch sitting on my dashboard so the next time it won’t start, I’ll try the new switch - presumably use screwdriver to turn the switch. At the moment, it starts every time - probably until I get somewhere busy!

Yes, although ideally something equally as soft as the switch so you dont chew it up for when you may need to fit it .
You’ll need a screwdriver to take the cowling off the steering column if you havent already taken it off

this happend on mine.

viewtopic.php?t=180671

Have replaced the wire running from the ignition switch all the way to starter and it hasnt happend since then...

Thanks for that. Sounds worth a go. Wouldn’t start first thing this morning so tried the replacement ignition switch. That wouldn’t work either, so not that. Of course, a little later it started happily.
Looked at back of fuse box and found a red and black wire going in to back but couldn’t find one going out? Also no sign of a red and black wire at the black box in the engine compartment - but maybe I’m looking at the wrong black box. Guess it doesn’t matter too much about the original routing if I’m to go directly from switch to solenoid…
Thanks all for help and advice.

Whilst I got to the bottom of this I made a temp wire with a spade connected to the starter then ran the wire through the van to the battery. Make sure you are in neutral, ignition on and touch the bare end to the battery positive… that should turn the van over… not great if you stall in traffic though

Just an update in case it helps anyone else. I guess this was a lesson in ‘the simplest explanation is probably the best’! Took van to Paul at K&N Motors near Barnstaple. He’s worked on type 2s and t25s for many years. He spent a couple of hours checking wiring etc. Took wires to starter off fusebox and joined them directly. No junction at black box at the back. Also put a live feed direct to solenoid. Started fine with this - at first. But, fortunately, it then wouldn’t start neither with ignition nor with direct feed. Tap on solenoid with hammer and it started fine. Diagnosis - faulty new starter motor. A decent Elstock motor from GSF and it’s been fine since. Tbf, Schofields have said it’s the first faulty one they’ve had but the Elstock one seemed much better quality - and cheaper.
Alls well that ends well! Thanks to everyone for help.