So I replaced the Starter motor on my 1990 GQ TD42 ute. Started fine and worked great.
Next day, I went to glow/crank the engine, upon turning the key to crank there was a clunk and then nothing.
Turned the key off and back on, only to find that there was now no power throughout the whole car (lights etc KAPUT), but that a relay was buzzing behind the battery box.
Investigated to find that it is the glow plug relay, so I swapped it, and the IGN (start) relay out for good measure. Replaced the 2 relays and had lights etc. again. Upon trying to crank however, done the same thing as before.
I checked the battery. It has 12.6 volts in it, so I don’t think its a worry, and is charging fine as well (threw it on overnight).
It gets even better when I find that when you unplug the glow plug (plug in front of the airbox on the intake manifold) from the Bus-bar (rail between your glow plugs) that the GP relay stops buzzing and seems to throw in and out as you would expect. Also that the soldered white with red striped wire onto your start relay doesn’t have power (I assume this would be the ’86′ part of this relay, with the 30 being the direct battery feed onto the stud terminal)
Have replaced all fuses in drivers side kick panel, and checked for power at the back of the IGN switch (has power) but no results throughout the car.
It gets even better again when I find that sometimes you get all lights working again fine, as if it was just any normal TD42, and then you attempt to crank followed by a large clunk and a massive arc from the plug into the Bus-bar if you have left it unplugged.
I get the feeling this is a combination of a shorted armature, and a buggered ignition switch. Thats what I am hypothesising
I’m a 2nd year auto electrician, so don’t be afraid to throw technical terms out, but this is just doing my head in… It’s probably something simple, but with all the stress (car has been off the road for 14 days attempting to fix this) I am worried I may have overlooked something, or the people with more experience may know a few tricks
Before you give me a serve about being a 2nd year apprentice in auto electrics and not being able to fix my car, I work away for 7 days on, 7 days off, and can’t exactly take the car into work to fix it
If anyone is able to give me some feedback it would be heaps appreciated…
I’m really missing my truck, and are going mental without the old girl