Ignition Dead

[Narboz]

Ive got a 1994 2.8L diesel Toyota Hilux dual cab. Wont start in the mornings or evening if cold. Got 280k on the clock. When you turn the ignition key there is nothing. Lights on the dash display and glow plug light comes on. Can clutch start the car. Once the car is running for a while and warms up, you can turn it off and it will ignition start every time. The battery, glow plugs and ignition barrel have all been replaced. Any ideas would be greatly appreciated.

[Manxman]

test starter motor and solenoid-expect worn brushes &/or rusty solenoid/bad contacts. Brushes are abt $20/set. Proper install can be expensive. Apparently they need soaking in motor oil for >8hrs b4 install. You should also have the armature tested for dead windings and the commutator machined smooth and undercut properly. Do NOT use lead solder to attach them, use the new electronics lead free stuff or silver solder-NOT lo temp!!!! DO use anti-wicking techniques. Check for bad connections at all hi current terminals, ANY deterioration is serious to a 12V 2KW motor.

[Manxman]

Starter pinion bearing prob needs replacing too. new replacement >$300- try ebay. repair shop might try to force new rather than repair-but repair is generally worthwhile. DIY is not physically difficult-but you DO have to understand what to do. The armature stuff you take to shop and pay for. they have the tools. While your at it, do the alternator brushes and bearings-they wear out abt the same time, and you are at typical failure milage. I can't walk you thru it this time, I'm going offline for a week or 2 tomorrow. Hopefully there'sd enough web info and help to see you through. Forumites should be good help.

Edited September 12, 2012 by Manxman

[Narboz]

Thanks, appreciate your advice. Will get the starter checked today and go from there.