Troubleshooting Peugeot Boxer Starting Problem (1 Viewer)

[Markyboyzz]

Hi folks, my Peugeot boxer has been turning over very sluggishly for a long time and last night something went bang.
She won't turn over, all electrics are fine ,battery is new ( I thought a new battery would resolve the the issue) and immobiliser light turns off as usual, everything pointed to starter motor, van is 19 years old and only 30k on the clock so I thought lack of use might be an iss

ue,tested starter and the bugger is spinning like mad so it must be something else, only obvious thing is the battery live connection is half broken, not sure if that's the issue, sounds a bit simple but if I'm able to post a pic I will, if anyone can identify the weird motorhome specific battery attachment adaptor that would be helpful as Google image search thinks its a fusebox

 

[Figaro]

tested starter and the bugger is spinning like mad

Is it spinning and not engaging ?
That may be the issue ?

 

[oldiesontour]

Does the solenoid on the starter operate and pull the starter gear forward?if so
Although not ideal if battery post and terminal are clean and tight should be ok to start,clean out it back together try to start if it doesn't get warm or spark,try cleaning engine to body earth strap both ends (body and strap) & battery to body earth strap.
Cut that nasty connector off and fit a new one,(battery terminal)

 

[Trevor Wbm]

From various Peugeot forums, I've learned that the earth stap from gearbox to chassis is prone to corrosion, and gets blamed for all sorts of issues, including this one.

 

[Markyboyzz]

Starter is spinning fine on test, will fit it back in tomorrow and I'll try and bodge a new connection, nothing explains the sluggish starting or the bang?

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[oldiesontour]

Starter is spinning fine on test, will fit it back in tomorrow and I'll try and bodge a new connection, nothing explains the sluggish starting or the bang?

Is starter dog pulling in ?

 

[oldiesontour]

I've had starters spin off vehicle but won't turn engine over.Before refitting check brushes in starter

 

[steve69]

Definitely sounds like a poor earth connection.
WD 40 is a good friend.

 

[arkwright]

I've had issues in the past with starter motors turning fine but don't when under load.

 

[jockaneezer]

A breaker's yard might be your best shot for the battery terminal gubbins as they're probably generic to most of their range of vans and that broken clamp will cause issues further down the line ?
As to the "bang" did it happen just as you turned the key ? Although it's not starting, can you hear the starter spinning at all when you try to start it ? It might be that the engagement solenoid and linkage have broken on the starter ?
If you go for a new starter, take the old one with you when you go to the motor factors and you should get a "service exchange" discount from the price of the new one.

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[Markyboyzz]

Hmm, OK, thanks for all the input, I've tested the starter motor and it spins fine, put it back in and made sure the battery is tight, cleaned up the connections, turn the key, not turning over, no clicks, nothing happens, after market immobiliser fitted but flashing light goes off as normal, I was convinced it was the starter because it started so sluggishly and had already purchased a new battery, everything else works fine just no turn over, info on the web is poor for some reason, is there a fuse that handles a starter motor exclusively?

 

[oldiesontour]

You didn't say if solenoid was pulling in before you refitted it

 

[Markyboyzz]

Thanks everyone, sorted now, I always assume the worst rather than considering Okams razor first, I tried a jump lead from battery to chassis and she started up good as gold, just need to find the termination point on the chassis and clean it up.
Thank you everyone for your help

 

[Markyboyzz]

Oh my, issue not resolved, euro car parts and wilco (wisbeach auto superstore) do not stock and are unable to provide a replacement earth lead, bit strange, I bought a generic earth strap, fitted new fittings to the battery and cleaned up the earth point on the chassis, still won't run unless a jump lead is run from the battery to a point on the engine, I'm wondering if its an additional earth point, apparently their might be one from engine to chassis, anyone have a clue of its location? Peugeot boxer 2005

 

[68c]

There should be a thick black cable from the negative terminal of the battery down to the chassis below the battery, then a braided cable from the chassis earth point to the engine. It is this braided cable that fails most often due to corrosion.

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[dunnah01]

Just fit any old thick wire from the engine to the chassis, you don't need to do anything with the existing earth strap.

 

[Two on Tour]

Oh my, issue not resolved, euro car parts and wilco (wisbeach auto superstore) do not stock and are unable to provide a replacement earth lead, bit strange, I bought a generic earth strap, fitted new fittings to the battery and cleaned up the earth point on the chassis, still won't run unless a jump lead is run from the battery to a point on the engine, I'm wondering if its an additional earth point, apparently their might be one from engine to chassis, anyone have a clue of its location? Peugeot boxer 2005

This is the gearbox to chassis earth strap position on our 2013 van but it's a pain to get to. It's on top of the N/S chassis leg and a spigot on the gearbox.

We had a 2004 Ducato PVC which was missing a gearbox to chassis earth strap and caused us starting problems, so I made a strap and fitted it to a threaded stud located on the underside of the N/S chassis leg and a bolt on the gearbox casing, which solved our starting problems.
You can get an earth strap made to suit on eBay.

Car Engine Gearbox Battery Earth Lead Strap 9 to 30 Inch Choose Terminal sizes | eBay

Find many great new & used options and get the best deals for Car Engine Gearbox Battery Earth Lead Strap 9 to 30 Inch Choose Terminal sizes at the best online prices at eBay! Free delivery for many products.

www.ebay.co.uk

 

[Markyboyzz]

Extremely helpful, I'll be under the van tomorrow, thanks everyone

 

[Markyboyzz]

Boom! It does not look healthy

 

[Two on Tour]

Could do with a bit of TLC.
What is the other end connected to ?

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[Markyboyzz]

Could do with a bit of TLC.
What is the other end connected to ?

Somewhere incredibly awkward, also, I'm going to need an eazy out, snapped the bloody head off didn't I, other end is impossible to get at without stripping stuff above from the bonnet side down, timebto look for alternative good earth's with a multimeter
Also I need to go on youtube to learn how to use a multimeter
I also need multimeter

 

[Two on Tour]

Somewhere incredibly awkward, also, I'm going to need an eazy out, snapped the bloody head off didn't I, other end is impossible to get at without stripping stuff above from the bonnet side down, timebto look for alternative good earth's with a multimeter
Also I need to go on youtube to learn how to use a multimeter
I also need multimeter

If there are alternative positions to attach an earth strap to the gearbox and chassis leg, then use those and forget about the original earth strap.

 

[GeoffnDee]

Markyboyzz If you look at www.aandncaravanservices.co.uk (earth strap problems ) there is a section about replacing the original earth cable , fitting one under the bonnet without needing to involve the original cable

 

[Jev88]

Add as many earth cables as you can. I added battery direct to engine block towing eye, left inner wing to gearbox (any convenient bolt will work) and finally towing eye on engine back to front chassis. Many gremlins disappeared. The main earth lead from battery down to inner right wing can rot from the inside out and have zero shielding from road spray.

 

[Markyboyzz]

Yup, your all correct, I used a multimeter and found a nice point under the bonnet, I connected straight to the battery, and again corr3ct, didn't need to touch the old earth point under the arch, I'm expecting some wire wheels from ebay so I'll scrape of some paint and fit a secondary one with my "wasted" new battery earth lead (£14.99).
Cannot believe how fast she now turns over and fires up, I estimate from turning the key to engine running about 1- 1.5 seconds, instead of the sluggish laborious not been run six months flat battery style starts of old.
Amazing how much difference a £5 earth strap from Halfords can make.
Thanks for all your help

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