PanamaImport

Sorry for yet another post on this topic, but I've been reading the myriad of old posts on no start/crank conditions and trying every troubleshooting tip I've found. Hopefully someone can point me to the next step. I don't want to order a new engine wiring loom unless absolutely necessary.

1986.5 928S Euro/ROW 16 valve, dual distributor, Manual. ABS disabled

I am unable to jump the car using the jump post and yellow wire pin (14 pin). Starter clicks and power goes out until I remove key and insert again. Same happens when trying to start at switch and when using jumper wire at start relay. Also, with the key ON, I'm not getting voltage at terminal 86 of starter relay. What does this indicate? Short or open circuit somewhere?

Here's mostly everything else I've tested. At least the stuff I remember:
- 12.7v at Battery, Jump Post, and Starter
- Near new battery, tested. Also tried another battery and no go.
- Near new hi-torque starter bench tested and works great
- Near new ignition switch. Relays click when turning key.
- Switched multiple relays around to confirm start relay is working.
- Brand new ground strap at battery + recently cleaned/deoxit all the main ground locations. Good continuity everywhere I've tested.

Happy to include any additional info. Just can't think of anything else essential at this time. Thanks in advance.

Mrmerlin

can you turn the engine over with a 27MM deep socket on the crank bolt?

PanamaImport

Yes. Just last week to check the timing and belt tension.

Mrmerlin

Ok so if you touch the #14 pin to the hot post stud the starter just clicks
Note #14 pin is the one closest to the front and closest to the fender

if so then the starter is bad replace the starter with the original and retest


Note if this is an auto perform a flex plate check

Petza914

If the starter on an 84 Euro S 16v is the same, I have one I'll sell reasonably.

I'd remove the starter from the car and bench test it with a spare battery.

PanamaImport

Thanks all. I was finally able to continue testing today and the good news is that I got the car to start after a few more tries. I knew the starter and battery were good because they were bench tested. Just not sure why it took so many tries for the starter to start engaging with the flywheel. I can now start it with the key and it's not making any odd noises. Fingers crossed this won't become an intermittent issue.

This quick video shows me trying to jump the starter before it actually engaged. You can hear the bendix come out but seems to hit the flywheel but unable to spin. I guess the gears finally aligned. If anyone knows why this was happening (eg.. shims?), welcome the input. -