TOP POST
Sounds like a fire hazard to me...
shakiro
Scroll down for diagnosis. Textbooks and FSM of no value.
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> Symptom: This is an intermittant starter malfunction. Most of the time,
> when the key is turned to "start" the engine cranks normally. Sometimes,
> however, there is a momentary delay before starter engagement. During this
> delay, there is no sound from the starter or solenoid. The delay can range
> from a fraction of a second to several seconds, but the engine always
> cranks. Sometimes it helps when the key is switched several times. When
> the key is in the start position, the engine warning light illuminates and
> the dash voltmeter dips. The engine is an inline four, turbocharged, fwd
> configuration. What caused this odd fail to crank difficulty? Answer > below.
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> The starter motor heat shield. The heat shield is a composite of
> insulation fiber with a heavy foil relector. When the shield deteriorated,
> the foil came into contact and shorted the relay-actuated solenoid power
> input terminal. When the switch goes to start, the solenoid terminal is
> partially or fully grounded, depending on the corroded foil surface
> condition. The unfused solenoid power input would arc or melt a hole in
> the foil, at which time enough current would feed into the solenoid to
> actuate it and close the starter motor contacts. From engine operation,
> the loosened foil would move about, sometimes shorting the terminal and at
> other times, not, causing a difficult-to-diagnose problem. When the
> problem was resolved, the foil was full of burned spots and holes. The
> starter and terminals are not readily visible for mechanic's inspection or
> attachment of multi-tester leads in this model, making the intermittant
> even harder to find.