cannot start my '96 corolla in cold weather

[zwhzjh]

My car is 96 corolla DX (1.8L) and the mileage is about 123k. Recently it has some problem when started in the morning. When I turn the key to the "on" position, it is still fine but when turning to the "start" position, it produces a slight "click" sound and then keeps silent. After a couple tries (each time a "click" and then silent), sometimes it seems that the car is going to start but finally fails. I have to turn the key a couple more times to make it start and this gets worse when the temperature is below 55 degree. This problem never happened at noon, or after I ran the car for a while and re-started it. At around 6pm when I want to go home from work, sometimes the problem happened, but I just needed to turn the key 1~3 more times to get it started. I don't think this is caused by the battery problem, because three years ago when the battery failed and I turned the ignition key, I could hear continuous "click" sounds from the starter. Furthermore, I replaced the bad battery on October, 2006 so it is still not so worn (anyway I will ask AAA to check it today). Does it mean that there is something wrong with the starter, which is what the mechanic said but he didn't perform an inspection (he wanted to charge $240 totally but I think I can get the part for less than $100 and replace it myself, although it may take 2hrs and a lot of labor)? He also mentioned that there is a leak in the fuel filter, which is not urgent but is it possible to cause the starting problem?

Thank you in advance.

[Rip The E Brake]

you don't hear a CLICK CLICK CLICK? Check the start contacts and starter solenoid.

[zwhzjh]

Thank you for the reply. I have modified my post. I can hear only one CLICK (which is the "pop" in my original post) each time I turn the key, and this problem doesn't happen when the morning temperature is warm (higher than 60 degree). By the way, how can I check the start contacts and starter solenoid? Is there any detailed instruction? Thanks.

[Rip The E Brake]

Originally Posted by zwhzjh

Thank you for the reply. I have modified my post. I can hear only one CLICK (which is the "pop" in my original post) each time I turn the key, and this problem doesn't happen when the morning temperature is warm (higher than 60 degree). By the way, how can I check the start contacts and starter solenoid? Is there any detailed instruction? Thanks.

Your gonna need to get under the car to check the starter. Make sure the contact points for the power wires aren't rusted or corroded. If they are, clean them.

Make sure your battery cables are nice and tight on the posts too.

[hungt1999]

I agree, it is classic symptoms of the starter contact failing. You probably just need to replace the contacts inside the starter ($20-30$).

You can remove the starter yourself, access is a bit tight though. Once you remove the starter, open it up and you will see that the copper contacts in there will likely be physically worn. Everytime the starter turns, there is a rotor that turns against copper contacts. These contacts will wear with time so you will obviously see some deep wearing groove in them

The starter is physically attached to the car by only two bolts. There is also one single electrical wire.

I accessed mine from the top engine bay by laying myself face down over the engine bay and extending my arms down below. I think I had to remove one or two things to get them out of the way, nothing major though (cruise control actuator cable I think)

[trife96]

Originally Posted by zwhzjh

He also mentioned that there is a leak in the fuel filter, which is not urgent but is it possible to cause the starting problem?

With the symptoms you described with the single click. It sounds like a bad connection, and no, I don't think your fuel leak will keep it from starting based on the mechanic saying it was not urgent. But I would still look into that issue soon. I don't think the problems are related. Pretty simple removal, 2 starter bolts, one comes in from the driver side and the other on the opposite side...kinda strange. Also it's easiest to remove the stock intake first. Get it outta the way. The cruise control cable can be basically just left alone in my opinion. I wouldn't remove it but it runs thru a little clip on the air intake along with the accelerator cable. So when you remove the intake, just pull the cables outta the clip...that's it. That's after you check your basic connections. Check for corrosion and tightness. Fuel filter has two lines, one on bottom and one on top. Kind of a PITA to change, it's mounted on the driver side on the firewall. You can get a good visual of it after you remove the air intake.

[Bitter]

i agree, check your battery cables. i had a rotten power cable near the battery to the starter that kept it from starting a few times.