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Thread: Intermittent engine non-starting?

  1. #1
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    Intermittent engine non-starting?

    Recently I noticed my car (1993 525i) does not start in the morning. All the dash lights power up and all electrical accessories work fine. But I just get a click sound when I turn the key.

    But after 5 minutes, car starts up fine. And for the rest of the day, it starts up fine as well. Battery at 12.6v and charge voltage at 14.3v so looks like battery/alternator are fine.

    Next morning, same thing. It's sort of annoying having to wait 5 minutes every morning just to start the car. Any clues?

  2. #2
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    Could it be the fusible link? What'ts the part number? i cant find it on Amazon

  3. #3
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    there are 2 fusible links, 1 goes from the battery to the fuse box under rear seat to power the GM, RM and other relays and fuses, and the most important goes from the battery inline in shrink plastic towards engine bay to power the e-box.
    19 Fuse B80 1 07119978840 http://www.realoem.com/bmw/enUS/show...diagId=61_0549
    the other one is not shown separately as it is part of 04 Battery cable (plus pole) +EGS 1 from 09/1992 12531703095 http://www.realoem.com/bmw/enUS/show...14#12531703095
    That one is riveted, you have to drill out the rivets and replace the fusible link, usually 50A http://www.bmwe34.net/E34main/Mainte...sible_link.htm

    also explained on my website http://twrite.org/shogunnew/data/electrical.html
    Shogun tricks and tips for the E32 series are HERE!

  4. #4
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    Quote Originally Posted by shogun View Post
    there are 2 fusible links, 1 goes from the battery to the fuse box under rear seat to power the GM, RM and other relays and fuses, and the most important goes from the battery inline in shrink plastic towards engine bay to power the e-box.
    19 Fuse B80 1 07119978840 http://www.realoem.com/bmw/enUS/show...diagId=61_0549
    the other one is not shown separately as it is part of 04 Battery cable (plus pole) +EGS 1 from 09/1992 12531703095 http://www.realoem.com/bmw/enUS/show...14#12531703095
    That one is riveted, you have to drill out the rivets and replace the fusible link, usually 50A http://www.bmwe34.net/E34main/Mainte...sible_link.htm

    also explained on my website http://twrite.org/shogunnew/data/electrical.html

    Thank you for all these infos!

    I noticed today a little trick to get the car started...simply press the brake pedal before turning the key. It has worked twice in a row now. I wonder what that;s all about?
    Last edited by RobbiesE34; 03-01-2018 at 02:35 AM.

  5. #5
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    Does the car have automatic transmission or is it manual transmission?
    Shogun tricks and tips for the E32 series are HERE!

  6. #6
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    Quote Originally Posted by shogun View Post
    Does the car have automatic transmission or is it manual transmission?

    Automatic.

    The brake pedal trick just lasted for a couple of days though. Now it does not start at all. I had the battery tested and it shows good with 12.3 volts. I changed the linkable fuse, but that didn't help. Dash board lights up when I try to crank. Stereo works too. But no crank.

    I am thinking maybe the General Module needs to be replaced?

  7. #7
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    There are TWO fusible links! Check them both. Which one did you replace. Only one goes to the e-box and that is the one difficult to find, as it is inline and with shrink plastic, the other one is for the electr. under the rear seat. Here are more pics https://www.bimmerforums.com/forum/s...=fusible+links
    The general module is only for central chassis electronics like door locking, interior lights, power winsows, power sunroof, headlight washer system etc, but has no relation with the engine control
    Shogun tricks and tips for the E32 series are HERE!

  8. #8
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    Quote Originally Posted by shogun View Post
    There are TWO fusible links! Check them both. Which one did you replace. Only one goes to the e-box and that is the one difficult to find, as it is inline and with shrink plastic, the other one is for the electr. under the rear seat. Here are more pics https://www.bimmerforums.com/forum/s...=fusible+links
    The general module is only for central chassis electronics like door locking, interior lights, power winsows, power sunroof, headlight washer system etc, but has no relation with the engine control
    I replaced the 80 amp one.

    Tomorrow I am going to try starting the car w/o the GM. I read that a bad GM could make the anti-theft device think the car was not opened with the key, and thus the car won't start...

    All the door locks work, but the interior lights don't. So I suspect the GM.

    But if that doesn't work then I'll go ahead and replace the 50 amp fusible link.

    Thanks!
    Last edited by RobbiesE34; 03-04-2018 at 05:30 AM.

  9. #9
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    80A is for the GM and other stuff under rear seat, the 50A fusible goes to the e-box in engine bay.
    Anyway, try the GM and let's see.
    Shogun tricks and tips for the E32 series are HERE!

  10. #10
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    Ok so I pulled the GM. Tried to start the car. Nothing happened. Same as before.

    So now I am looking at the 50 amp fusible. It was very hard to get too. The cable is so short. Anyhow I pulled the heatshrink, and it looks to me like the fusible is good? What do you think?

    IMG_20180304_134347664.jpg
    Last edited by RobbiesE34; 03-04-2018 at 04:51 PM.

  11. #11
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    From the pic it looks o.k., and I assume no small haircracks under the rivets. Better measure with a multimeter between the 2 red cables.
    Now someone with special E34 electric knowledge has to chime in, if the problem is not the 2 fusible links.
    Shogun tricks and tips for the E32 series are HERE!

  12. #12
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    When I turn the ignition, I just hear 1 click.

    Not a series of clicks.

    Is that a clue of a bad starter?

  13. #13
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    Where is the one by the ebox? When you say ebox, are you referring to the fuse box? Having a similar situation in mine. Sometimes car is very hard to start, as if there’s not enough juice from the battery.

  14. #14
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    Quote Originally Posted by RobbiesE34 View Post
    When I turn the ignition, I just hear 1 click.

    Not a series of clicks.

    Is that a clue of a bad starter?
    Make sure the engine to body ground is in good shape. Maybe take it out and clean it up and the clean the spots on the engine and body that it attaches to.
    demet

  15. #15
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    Any other grounds on the car?

  16. #16
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    There are many ground cables on the car, but in this case the one from engine to chassis is important. Fusible link pics are here https://www.bimmerforums.com/forum/s...t=fusible+link

    "Where is the one by the ebox? When you say ebox, are you referring to the fuse box? "

    which built year? e-box means the electronic box right hand side where the DME etc is located.
    For example 1989 E34 http://shark.armchair.mb.ca/~dave/BMW/e34/e34_89.pdf see page 0670.2-00 there you see the fusible link, then go to 0670.2-05

    The starter is not connected to the fusible link, that is directly connected to the battery. The main relay and the fuel pump relay are connected to the fusible link.
    I would check the ground cable from motor to chassis
    Last edited by shogun; 08-03-2018 at 12:48 AM.
    Shogun tricks and tips for the E32 series are HERE!

  17. #17
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    Does the dealer carry the fusible links?

  18. #18
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    Bang on the starter and try again. Also try cleaning the contacts for the neutral safety switch, doesn't hurt and it's free if you have some rubbing alcohol.

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