Intermittent starting fault.

[Smoothym]

Hi
I've had issues with my 2008 Stelvio for at least 2 years on and off.
The problem occurs when starter button is pressed. sometimes nothing happens, just a relay click from the front R/H Auxiliary Fusebox.
I had gone through many possible fixes including adding a new relay in the circuit as the feed current to starter seemed to be the issue - Cured!

Then the problem occurred again this time i gave the Auxiliary Fusebox a wiggle and - start up straight away. This became more regular until I decided to strip it out and see what can be found - assuming a broken wire or bad contact.

The Auxiliary Fuse box is now accessible but have now got another issue. As nothing is obvious I intend to pull out each spade connector and re-crimp each terminal.
My problem is I cannot remove the spade connectors from the Auxiliary Fuse Box base. I am assuming they have retaining tabs to hold them in but cannot get them out ( the yellow base has been unclipped and slid away from the block).

Does anybody have any suggestions.
Regards
Mike

 

[draidt]

https://www.guzzitech.com/forum/196/4908.html

 

[Rafael]

Do a load test on the battery just to make sure it's not that. The source of a given symptom sometimes changes over time.

The spade wire terminal in the connector is a latch type spade. Before taking everything apart you'd might try spraying DeOxit on the terminals. It should make a difference if the crimping is the source of the problem.

Have the latch spade terminals on hand before starting, they're not so easy to find. The regular spade won't stay in the block. To get the spade out you'll need a special tool, I made one from a flat bobby pin. Just slightly bend about 1/8" of the tip. Insert the bent part toward the latch to dislodge it then pull the wire out.

Search for the threads on GT to find more info on the subject. I ended up rewiring the power source to the relay for the solenoid. Haven't had a nonstart since.

 

[WayneOrwig]

As Dan linked to, it may be the so called 'starter interuptus'.
They pass the starter solenoid current through a fuse, then to the ignition switch, then through a second fuse, then to a relay contact, then off to the solenoid. The relay does not get good power from the battery, but rather it gets weak power from the ignition switch. No idea why they do this.
What often happens is that the 30 or more amps needed to initially pull the solenoid can't make it through all of that stuff. In particular, the ignition switch contacts get weak and corroded, and can't pass the current.
I would pull the fuses and relays and spray the contacts with a contact enhancer, like Caig Deoxit.
Load test the battery and clean the terminals, plus clean the main fuses contacts near the battery.
Look into disassembling the ignition switch and cleaning those contacts.
On the Norge and Breva, a number of owners have run a wire to feed the starter relay directly from the battery instead of the ignition switch and cured the problem. Not sure what it would take to do that on a Stelvio.

 

[Smoothym]

Thanks
The bent pin idea works well with the lugged connectors.

Battery is fine, new one last year, all voltages are healthy.

With regard the voltage issue, I have been aware of this in the past which is why i used the original starter solenoid feed as the switch line for a new battery to starter solenoid relay.

I will clean up the contacts and see what happens.

Thanks

 

[RonStelvio]

A little relay trick I used with the V11... Tweek/twist the relay spade terminals slightly (about 5 degrees) and reinsert into the plug. Worked for me... alongside the road... far from home.