Originally Posted by IndianaJones
I am so annoyed, which is why I am here asking people with a better understanding of motors for their thoughts.
Therefore, the question is:
If a faulty Starter Motor (Or one that was not fully compatible) was put into the van back in November 2017, could this have affected the Alternator, Starter Relay or Ignition System.
Problems over the last 9 months include having to hit the Starter Motor with a lump of wood, and since having it replace AGAIN having problems getting the Starter Motor to engage.
If hitting the starter motor resolves the issue, chances are the starter motor itself is the fault.
Turning the key in the ignition repeatedly before the Starter Motor engages must be putting an electrical strain on something, or maybe an additional fault was caused in the 9 months living with a faulty Starter Motor?
Every time you turn the key to the start position there is an infinitesimal amount of wear on the switch and it's contacts, and at some point the switch will wear out and need to be replaced - I just swapped out one on a twenty year old car.
A couple of comments ...
First - I don't think an 04 Carry has a starter relay per se
, it does have a starter solenoid, which handles both engagement of the bendix and switches the current to the motor, but that's typically considered a part of the starter motor and replaced with it.
Second - the starter electrical system is a very simple circuit and as long as the "delayed start" symptom is consistent, it should not take a competent auto-electrician more than a few tries to pin down which part of the circuit needs to be looked at - whoever told you that there wasn’t a fault, that was just the way it goes was BSing you and your mistake was accepting that when you knew from previous use of the vehicle that there was a fault.
Third - the alternator output has nothing to do with the starter engaging or not engaging - there is no alternator output until the engine is started - the alternator charges the battery, and the battery starts the car - if the battery is flat, or discharged, and too weak to start the car, then you can blame the alternator, and you will know this is the case when the starter engages and cranks slowly - so to speak RRRR - RRrr - rrrr - followed by silence.
Because of the prolonged time span, you may have multiple faults, a worn ignition switch is one, a defective starter is another, the clutch or neutral safety switch (if fitted) are other suspects - put a test light on the starter solenoid control terminal and turn the key to start - it will either light or not - light and no crank is a defective starter - no light no crank would indicate a fault external to the starter and would require a more detailed examination.
Whilst knowing the "back story" is good, it does not help to pin down the problem area, that needs "hands on" investigation by someone with knowledge & experience.