Engine won't crank...out of ideas.

[Leo87]

Hi everyone, I need some help please. I have an '05 Regal with a Volvo 4.3 GXi-E. Towards the end of last season I've been having a no crank problem. I turn the key and nothing happens. No clicks or anything. After a few tries it suddenly cranks and starts right away. It is getting harder though. I need to turn the key more times to make it work. All the lights, beeps, etc do come on. I can also hear the fuel pump pressurizing so the kill switch is good. I replaced the Ignition switch assuming that was it. I was wrong. The problem is still there. Both batteries are fully charged and with plenty of juice. I even had them tested at the battery store. Today I tried bypassing the Neutral Safety Switch by the control (Teleflex SL-3). No difference. I then removed the cables attached to the starter solenoid, cleaned them, and re-attached them. No difference. I also cleaned the battery terminals and cables. I checked all fuses and all look fine. I am thinking maybe there is another safety switch somewhere that is going bad? I am out of ideas. Appreciate any suggestions anyone may have. Thank you.

Nelson

 

[Bondo]

Re: Engine won't crank...out of ideas.

I then removed the cables attached to the starter solenoid, cleaned them, and re-attached them. No difference. I also cleaned the battery terminals and cables.

Ayuh,... What about the Grounds,..??

It takes 2 legs to complete a circuit ya know....

 

[Leo87]

Re: Engine won't crank...out of ideas.

Sorry, I forgot to include that. I also removed them and reinstalled them. At least the ones I could see. There is a gound bar that connects a cable coming from the engine, and then the ones from the batteries. They all looked fine but I brushed them just in case. Thank you for the quick reply Bond-o.

 

[allingeneral]

Re: Engine won't crank...out of ideas.

Sounds like the starter solenoid to me. Have you replaced it, or just disconnected it and cleaned up the terminals?

 

[Leo87]

Re: Engine won't crank...out of ideas.

I only disconnected it and cleaned up the terminals. What is the best way to test the solenoid? I do have a digital volt meter. Is it normal for it to slowly go bad? It does work sometimes. Thank you.

 

[Bondo]

Re: Engine won't crank...out of ideas.

Sorry, I forgot to include that. I also removed them and reinstalled them. At least the ones I could see. There is a gound bar that connects a cable coming from the engine, and then the ones from the batteries. They all looked fine but I brushed them just in case. Thank you for the quick reply Bond-o.

Ayuh,... Then get a Test Light, or DVMeter, 'n follow the power through the start circuit...
It's Waaay cheaper than just throwin' parts at it, Hopin' to get it right...

 

[Don S]

Re: Engine won't crank...out of ideas.

Have you checked the start relay and fuse for corrosion on the terminals?

Just so you and everyone else understands, Volvo forgot to make a wiring diagram for this electical box on your engine, and it's the only year that used one like it.

 

[Leo87]

Re: Engine won't crank...out of ideas.

I just checked with my test light. Power gets to the solenoid. I also checked the starter relay. Looks fine but who knows. The fuse was good too but I replaced it with a spare one just in case. No rust anywhere. I do have a remote starter so I am going to try that next. Thank you all.

 

[03232001]

Re: Engine won't crank...out of ideas.

You mentioned you have a digital meter, but is it a multi meter. to test your solenoid you will use ohm's not voltage or amperage. You have the smaller gauge wire from the key switch going to it and then you have the larger gauge wires from battery on one side and to starter on the other. Remove them both so you don't have live power to deal with now when you energize the key switch wire it causes the circuit to be internally transfer across the 2 lugs that the larger gauge wires were connected to using the ohm setting on the meter can give you a resistance value. Using this method you can tell if current (AMP's) are flowing freely A zero reading means no resistance. You can use this method for checking everything in the system Key switch, fuses, wires, connectors, from lug to lug on a grounding block, and everywhere your power supply is supposed to flow to. Remember make sure there is no power to anything your checking (VOLTAGE) because this check is substituting resistance for voltage if you have power it will damage the meter and be dangerous to you. Anything that has corrosion, bad ground, or damaged will result in either a higher reading or no reading. Its hard in just one post to try an portray electrical theory but do a search on resistance checks and see what hits ya get and READ,READ,READ knowledge is key

 

[Don S]

Re: Engine won't crank...out of ideas.

I just checked with my test light. Power gets to the solenoid.

You have to do your testing while the problem exists. Intermittent problems can be difficult to locate.

 

[Leo87]

Re: Engine won't crank...out of ideas.

Thank you all and 03232001 for your details explanation. The location of the solenoid is fairly hidden so I opted for looking for more grounds. I could not connect my remote starter switch to bypass the starter relay so I couldn't do that test. I found another bridge with a few connectors. I removed them all, cleaned them, and re-installed them. On the first try nothing happened, but on the second one it worked. I tried 2 more times and still worked so who knows. Time will tell. I have the feeling I still have an issue. I'll do more testing when it happens again. Thank you again for all your help everyone.

 

[Don S]

Re: Engine won't crank...out of ideas.

One of the problems with testing and following the wiring for your engine is the lack of a wiring diagram for that engine. Seems Volvo didn't make a wiring diagram showing the fuse and relay box for that mode. They also only used that particular setup on only the E model. I did find a 2005 training manual that actually shows the wiring (kind of), I will mark it up and post if for you when I get a chance.
You might want to disconnect the GREEN connector going into the relay box and have a look at those connections to. Especially look at terminal 4D in that connector. That is where power from the ignition switch connects to the box and wiring to the relay. If it's corroded, you won't get a click or anything from the relay or the starter solenoid.

 

[Leo87]

Re: Engine won't crank...out of ideas.

Sounds great Don. I'll check it out. Thank you again for you all your help.

Nelson

 

[Don S]

Re: Engine won't crank...out of ideas.

Here's that bit of wiring diagram for the fuse/relay box, it's kind of big, but that was just so it would print out better.

 

[Leo87]

Re: Engine won't crank...out of ideas.

Great! Thank you Don. I ran out of time today. I'll check tomorrow and let you know how it looks.

 

[Leo87]

Re: Engine won't crank...out of ideas.

Well, looks like the problem is gone right now. I tried a few more times today and it cranked every time. Hopefully it was just a bad ground. I sprayed them all with electric contact cleaner too. Thank you again for all your help everyone.