L300 wont start when engine is warm. Looking for some help.

[rouxel]

Ok, so i bought this van a few months back knowing it had an issue starting when the engine was hot. Its a great van other then this issue.
I haven't really had any issues with it thus far because of it being winter right now, although I have had a couple. This is the best way I can explain whats happening.

Its a 1993 L300 super exceed diesel. The problem doesn't happen every time the engine gets warm, it just seems like it is completely at random. the only pattern that I have been able to pick up on is that it is much more likely to happen the warmer the day. -20 Celsius it will pretty much start every time, maybe 1 of 100 it wont start. Since it has been a little nicer the past couple days (plus 10 or so) its not starting much more frequently, maybe 1 in 5 times it wont start when the engine is warm. other then that, Im not sure why it wont start. the previous owner had a glow plug override switch installed and a turbo timer. Im not sure if that has anything to do with the problem. the only thing i have replaced was the starter relay and that didnt help. I can always tell when it wont start because when i hit the glow plug override switch i cant here the click. when I can here the click it always always starts. on the attempts that it wont start all i can here when i turn the key is a clicking sound every 3 or 4 seconds but It wont even turn the starter. No noise at all except the clicking as i turn and hold the key. I usually have to lift up the seat and let it cool down for about an hour before it will let me try and turn it over.

I have never once had an issue first thing in the morning and it always start when I leave work as it has had 8 hours to cool down but if i get gas or groceries there is a real chance, especially as its getting warmer, that im gonna be stuck there.

has anyone heard of or experienced this problem?

As im typing this my van is at the lake and wont start and my dog and i had to walk home. haha.

[Big-Bird]

There has been some chat about electrical connector issues at the battery. Check there for signs of melted plastic, corroded connections, worn insulators.

[JRM21]

Sounds like an electrical issue. If I understand correctly, you hear a click everytime you turn the key all the way over into the 'start' position? If the starter relay is clicking but the starter motor isn't moving then there is probably a break in the connection either between the relay and the battery, the starter and the battery, or the relay and the starter. I'm not sure why that would only happen when it's warm though.

If you keep a multimeter in the van you should be able to figure out where the problem is pretty quickly next time it happens. First check the black and red wire going into the starter relay for voltage. Then check the black and red wire going into the starter motor for voltage. Then check the wire running from the starter relay to the starter motor for continuity (it should be black and blue coming from the relay, and black and yellow going into the starter). I'm guessing the problem lies in one of these wires.

[john clem]

also a suggestion , multimeter on battery, should not drop below 9.6v on cranking attempt, possible intermittent short in battery, clean to shiny all connections on battery if still then could be loose armature in starter can sometimes short and draw battery down but then starter would get hot.>>keep up detective work hmm, unusual one, not quite clear on the different clicking but a bunch of clicks trying to turn engine over usually means not enough current to starter.>>good luck>>john

[rouxel]

I finally had a very quick chance to take a look at it. It hasn't happened in a while and today it did while i was at work. When I was leaving work I knew right away it wasnt going to start because when i hit my glow plug switch it didnt make a noise which means its not going to turn over. So I kinda got in there to take a look. I think that you may be right with the power to the starter but cannot be sure. When I checked for voltage to the starter from the battery it was saying volts but its hard to reach and see what you are touching. Anyway I think I was touching it and the volts would jump from 3 to 8 and then down and all over the board it seems but then again I may have not got a good connection when I was in there. As I was trying to get a reading, all of a sudden i had 12.3v. I got out and pressed my glow plug switch I heard the click. Started right up. So I guess im going to get in there and check the connections for corrosion and what not. Still dont understand why it only does it when its warm tho.