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Intermittent Starting Problems - Mysterious Cause Identified and Fixed
Evo GeneralDiscuss any generalized technical Evo related topics that may not fit into the other forums.
Please do not post tech and rumor threads here.
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Here’s my solution on a 1990 Talon: A dedicated starter circuit fired by a heavy duty 50 amp momentary pushbutton switch. The circuit bypasses the ignition switch and every other gizmo that would otherwise be in the circuit. One wire goes straight to the battery with an inline 40 amp fuse, the other wire plugs into the starter relay socket, where the outbound relay pin would normally go. This takes the 30 amps or so to the starter solenoid. So now the ignition switch is used only to turn on the ignition. The 3 flip switches and red LED are just other things I needed to mount someplace. I made the aluminum plate and its mounting brackets to accommodate the radio, boost controller, starter button, the 3 flip switches and the red LED. The starter switch is the one I showed back in post #69.
Like several others, for some time I have experienced an intermittent starting issue, whereby turning the key results in a 'click' from the starter relay, but no starter action. Sometimes I needed 20-30 turns of the key before it would suddenly turn over as if nothing were wrong. Strange indeed.
I invested several hours in checking starter, starter solenoid, and starter relay, but all seemed to work just fine when jumped with a power lead straight from the battery. I had already replaced the ignition switch and starter relay a year or so before - no improvement. A new starter and solenoid made no difference either.
I removed kick panels and the console to locate and check various connectors and starter circuit wiring. All connections checked out ok. I noticed whenever I sent power through the starter switch area, that's where trouble kept rearing its ugly head.
Some accused the start interrupter of an alarm system of being faulty. I also have an alarm system that taps into the starter circuit, so I disconnected it and verified that the problem was not resolved.
What I found after much aggravation is the problem is at the starter switch. It isn't the switch itself, but its tendency to rotate ever so slightly when the key is turned. See the photo below:
Remove the lower and upper steering wheel shaft covers, and the starter switch is revealed. The switch is held in place by only one screw. If this switch rotates by so much as a couple of degrees when the key is turned, you will hear a click, and no starter. Remove the starter switch (angled phillips wrench) and activate it with the key while holding in your hand. If you find the car starts every time, you've found the problem.
If you've done any wiring (e.g. alarm) under the dash, be sure you've not done anything to put downward pressure on that bundle of wiring from the starter switch area (see red X). If yours was like mine, you could be sorry. If anything, you want a little tension nudging those wires upward here, which can be done with wire ties.
There is a smaller, white connector assembly that triggers the 'ding dong' key alert sound. It mounts to the underside of the starter switch via a little plastic bracket and puts some pressure on the switch as a result. We don't want it tugging on the starter switch. Remove it from the starter switch and let it hang on its own (see green arrow).
Be sure you tighten the starter switch screw snugly (see purple arrow), and be sure the switch is rotated as far as it can be moved clockwise. Like I said, even if it rotates just a couple of degrees counterclockwise, it will cause trouble. It's hard to believe this area is so sensitive, but it is what it is. That being said, be gentle when you turn the key to start the car.
Many have the same problem. It's simply a matter of time before they become concerned enough to do something about it, and hopefully, find this discussion before changing every component in the starting system to no avail.
Thanks for this thread. I was stranded and had the same problem. Luckily I left my multimeter in my car for work. I found it weird that my battery wasn't draining when I tried to start it. The previous owner had a car alarm and turbo timer tucked under the dash and I think it was stressing out these wires. Relocated some stuff and zip tied. Thanks again OP.
Replaced starter, starter cable, and ignition switch with no limited success. I believe my problem is now solved. Installed a heavy duty starter relay and working flawlessly.
DIY can be found on post 148 in this thread. Recent heat wave in SoCal provided opportunities to test back to back starts with hot/humid engine bay conditions. Car started consistently every time. Been on the setup for 2 weeks. Thank you so much Ted B
So it their a recall or any tsb about this ongoing problem I'm a mechanic and still I found ted's post super help fullI had been going ape chasing this. Thanks know I know the problem I hope to not have it any more
Last edited by Todd Minutella; Oct 25, 2015 at 09:17 PM.
I am unaware of any TSB published as a result of this issue. It is certainly deserving of one. I'm glad this discussion helped you. I'm sure many others have had it, or will have it at some point.
this is why I love these types of communities. Soo much bs yet useful information for random *** problems!! Saving for later in the event that I ever encounter this problem.
After a year and a half of fighting this issue I can finally say it's fixed. I used a lot of the steps found in this thread and eventually I think mine was related to a bad main ground point. Either way the troubleshooting found here is sound. Thank you to the OP, Ted and all the others who put in the effort to help the rest of us.
If any one would like further details as to how I fixed mine just let me know.
Going to try some of these steps my self being having issues with my car lately. I bought a new ignition switch and i still have the problem. We'll see what happens when i try these steps.
Make sure to check the power cable going into the starter motor too. Most of the copper strands on mine on the connector going into the starter broke, causing intermittent starting. The connector is exposed to all the weather, and isn't really insulated either.
Replacing the ignition switch works sometimes, but in my case (and with others), the problem returned when the new switch assembly also began to rotate, thanks to that single small anchor screw. When this occurs, one can simply anchor it tightly using two wire ties, which I described in post #83.
