200DI problem.

Hi guys, thanks for letting me join. I am in Stoke on Trent and own a 1967 Series 2a 109 which I have had for 32 years and a 1992 Series 1 Discovery which I have had for 20 years.

My old series has had a 200di installed for a few years now and I have had no problems with it until recently.

When cold she starts no problem, first turn, but when run for a while then turned off refuses to start.

The symptoms are like the battery is totally flat, then when cold starts first time again?
Any of you guys come across this problem.

I have load tested the battery and ok, I have removed all the ground cables cleaned and refitted, I even have a new starter on and still get this prob.

Hope you guys can shed some light on this prob.
Thanks.

Are you saying it doesn’t crank once warmed up?

Sounds like its seizing up, then freeing off when cold

I run it yesterday about six mile or so when home turned off then started again no problem, then another short run after an hour or so to drop a gearbox off, left motor running then when home turned it off then tried to start again and it is if the battery is totally flat 1 or 2 turns then nothing?

300bhp/ton said:

Are you saying it doesn’t crank once warmed up?

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Yep, a couple of turns then nothing?

Has to be electrical. You are going to have to check wires and voltages. Such as test the alternator. Is it charging? Maybe even just try a new battery and see if it solves the problem.

Then start seeing what is going on where when the issue occurs. Have you still got good voltage in the places yous should such as battery and starter? What happens if you try a jump pack or jump leads on?

Basically lots of things you need to try and test and see what happens. Doubt anyone will be able to diagnose much further over the internet. Not without knowing answers to some of the questions.

What's the set up for starting, on the key or push button on the bulkhead?

Thanks 300bhp, time to get the multimeter out and get testing. Let you know the results when I get it done in between a myriad of other jobs Thanks again.

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tottot said:

What's the set up for starting, on the key or push button on the bulkhead?

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Hi Tottot, on the key.

Do the headlights come on when trying to crank when warm
Have you got clean brass on the connectors going to starter and tight ( cleaning earths is good do the same with positives)
Is the small wire and terminal to starter solenoid clean and sound is the connections to ignition barrel sound and tight
Try a flying 12v lead from battery direct to above terminal when it won’t start

Thinking on this some more. I’d maybe be looking for a cracked or broken wire. Cold the insulation might be stiff and hold it in place, once warm it could be more bendy and have poor connection. The loom running behind the engine from the started could be a good place to look. Although if it is slow cranking it suggests low voltage to the starter. So important to check what volts you are seeing when the problem occurs and where. I’d start at the battery and work my way along the wiring. But also prudent to check that the alternator is working too once running.

Hi guys,

Thanks for your input, I have done some testing this morning and here are the results.
Battery before starting 12.50v
Load test on battery holding at 10.2v
Engine running on tickover 14.50v
Tested chassis to engine block 14.38v
Neutral to starter bolt 14.38v
Lights heater etc on tickover holding steady at 14.38v
All earths cleaned and tightened.

What 300bph has said seems feasible, I did fit a new loom albeit many years ago but by now could have worn or be breaking down.

Thanks guys, more investigating to be done.
Whoever said retirement was cushy and relaxing

300bhp/ton said:

Thinking on this some more. I’d maybe be looking for a cracked or broken wire. Cold the insulation might be stiff and hold it in place, once warm it could be more bendy and have poor connection. The loom running behind the engine from the started could be a good place to look. Although if it is slow cranking it suggests low voltage to the starter. So important to check what volts you are seeing when the problem occurs and where. I’d start at the battery and work my way along the wiring. But also prudent to check that the alternator is working too once running.

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Hi 300,

Done some more investigation as per your post, let the engine run for approx 45 min to see if the problem is there when not been out for a run and yes it is.

This is a fairly new loom which is run high and anchored well above the engine, I was feeling and tugging at the wires while the missus turned the key still the same?

I am wondering though if it could be the starter switch as everything else seems to check out ok?

I have just ordered a new starter switch and will let you know the results in due course.

Thanks again.

You can get full voltage through a dodgy connection with a meter, but try to put a decent load through it and it'll fail. I'd just take apart all the big current connections and clean them.

As you have no turbo fitted you must have clear line of sight of the starter solenoid?

boguing said:

You can get full voltage through a dodgy connection with a meter, but try to put a decent load through it and it'll fail. I'd just take apart all the big current connections and clean them.

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Hi,Boguing,

Thanks for your input, I have taken everything apart cleaned terminals and seatings even a new starter motor fitted?

lynall said:

As you have no turbo fitted you must have clear line of sight of the starter solenoid?

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Thanks Lynall, new starter motor fitted.

18Wheeler said:

Hi,Boguing,

Thanks for your input, I have taken everything apart cleaned terminals and seatings even a new starter motor fitted?

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You probably have but I need to ask - and the earth straps?

Edit. Sorry, I see that you have.

Try taking a lead from battery +ve to the ignition feed wire connection on the solenoid. That bypasses a possible fault in the wire and switch.

boguing said:

Try taking a lead from battery +ve to the ignition feed wire connection on the solenoid. That bypasses a possible fault in the wire and switch.

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Thanks Boguing, I will attach a temporary lead to the solenoid while the engine is cold and run it towards the battery as I have moved it inside, easier to attach then when the engine is hot.