5-Series (E12,E28, E34, E39, E60)Chat relating to the BMW 5-Series of all generations. Specific models include: BMW 518, BMW 520, BMW 520i, BMW 530i, BMW 528i, BMW 530i, BMW 518i, BMW 524d, BMW 525i, BMW 525e, BMW 528e, BMW 540i, BMW 535i, BMW 520d, BMW 525td, BMW 525d, BMW 530d, BMW 525i/xi, BMW 530i/xi. (BMW 5-Series Forum)
My 1998 540i has a starting problem that is progressively getting worse. When the ignition switch is rotated to the start position a solenoid "clack" is heard with no starter activation. Usually, with repeated turns to the "start" position, it will eventually crank. The problem has been going on for several years and is getting to the point that I am nervous about taking the car out.
1) The battery condition is good. The voltage checks at better than 11.5 volts even after extended time parked. The lights remain bright. This problem has occurred even when getting a jump-start from an running donor vehicle.
2) At one point there seemed to be evidence that the clutch position sensor was preventing the start but this was inconsistent. The solenoid "clack" always occurred which did not seem consistent with a switch problem.
3) I replaced the original starter with an aftermarket unit. This seemed to cure the problem for maybe a month but the symptoms returned.
I would still suspect the starter as your alternator seems ok.
What did you do with the old starter? I would have had that one reconditioned...
A solenoid will sometimes still click even if it's starting to fail, this could simply be dirty internal contacts - same applies to relays too but they are usually cheap enough to replace.
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