Won't turn over if CABIN is freezing

[Black Magic]

Yes - title is correct! Anyone got a bright idea after reading the symptoms below?

I have been having problems if the temperatures are around 32 F or lower with the Disco II. If its higher than that I have no problems at all starting.

I turn on the ignition, all the lights come on as they should, the climate control fans turns on - I can turn that off OK, but there is still a slight whirring like a fan behind and left of the steering wheel - like a vacuum pump for the climate control? Happens even if Cruise switch is off.

I turn on the ignition to start her, the clock turns off as expected, I hear a relay move INSIDE (But not a definite CLICK/CLUNK) and then nothing - not even the starter solenoid moving like when a battery is low. Putting the charger on @ 60A doesn't help - and its a new battery (New since I first had the problem)

I put a fan heater under the engine for a while - alternator surface is warmish to the touch and I try again - same issue.

Put the fan heater INSIDE THE CAB and bring up the temperature to around 50F... Now she starts without hesitation.

Thats as far as I have got tonight - wondering if anyone has run into something like this before.

[Disco Mike]

I would suggest you track down that relay clicking sound, to me, that would be the problem because I never hear a relay noise at all when starting by truck. In Colorado we have been having some 11 degree days and I am not hearing anything unusual and she starts right up.
Mike

[Black Magic]

Played with it today, it was a bit warmer and I had no trouble kicking it over and starting. Of course I did leave the heater turned on in it all night .

The relay clicking on (or off) is heard if you turn the key VERY slowly from "Run" to "Start" - it happens a couple of degrees before the starter motor hits.

I'm guessing the starter relay inside has water freezing it... I've had a problem with the AC drain dripping into the passengers footwell, and maybe there is some inside a relay preventing it from moving/closing.

Leaving it outside tonight with no heater to see what happens in the morning.

Next problem is that I don't have a SII service manual - only a SI

Is there a resource online that has the relay locations?

[Black Magic]

UPDATE: Finally had available time, weather, and a wiring diagram...

The power goes:
(Under bonnet/hood) Battery ->
(Inside Cab) Fuse -> Ignition Switch
(Under bonnet/hood) Starter Relay
(Inside Cab) Body Control Unit -> Ground

I have ground at the starter relay so the Body Control unit is taking one side of the relay coil to ground. I have 12V on the relay contact from the main relay.

Shorting the 12V to the high side of the starter relay cranked the engine and started her up (Key was in the "Run" position)

So now I'm looking at the fuse, ignition switch, or wiring in the cab when I get the time. None of these items look like temps below 0 C / 32 F should affect them but

[Black Magic]

Wow - this is a weird one.

It seems that the problem cleared itself after doing the above stuff. Temps have been a little warmer - but I have had it start with out a problem in -6 deg C (inside) temperatures. I'm not convinced its gone, but it looks likely.

Next step is to tear the inside apart and see why I was getting AC condensate in the passengers footwell.

[Tracker]

b4 tearing the inside apart ,slide under car and clean nipples (drains).should find them above gearbox.be careful you may cop a cold water shower.
they block quite often here in oz(from dust/mud.

[Rovin4life]

the relay is energized by the neutral safety switch. if the bcu sees the signal it powers up the relay. I bet your neutral safety switch underneat might be the problem.