wiring from battery to starter

[ermie571]

Covkid that is a brilliant write up....I read it three or times at work and have printed it off as well! I don't have the blowtorch but I know a man who has! I can get the cable and connections and fit it myself....let's face it....it isn't going anywhere. I think I shall bypass the post in the black box in the engine bay as well.

Thanks again. .

[Oldiebut goodie]

You could also use a gas ring on the cooker for something this size - at least you won't have to hide it from 'er indoors!

[CovKid]

Now, can't remember exactly where (think Home Bargains) but it was a cuiinary blowtorch that can be refueled with gas lighter fuel and saw it within the last week. It was only about a fiver. Looked perfect for the job I thought.

Note my conclusions on the way alternator wire went to black box in engine bay and why I changed it.

[ermie571]

Oldie...I am er indoors lol. Covkid...yep noted your thoughts....we had the same discussion with a mate when we cleaned it all up around the post I think probably 5 years ago....

Anyway....have taken pics of the starter connections on ermie. .., much smaller[URL][/URL] grade cable ...

And it looks as if the actual cable does not fill the clamp unlike the other one


And a bit closer...


So...do folk think this may be an issue?

Thanks again

Em xx

[CovKid]

There are mixed views on bolt/screw and crimp connectors but I honestly think for battery/starter connections it should all be soldered and no strands left uncared for - in an ideal world. That way you're using the full capacity of the cable and get a far better connection from the outset. Mine was pretty much like that, only worse with all the corrosion. There are other cables, like the one from battery to ignition and ignition to fuseboard which I've yet to tackle but certainly getting a good connection between starter and battery is essential.

To be fair, your main battery cable (the black one) doesn't look TOO bad but it'll also depend on what its like at starter end. Can you get some photos of cable that end?

At the battery end, I always think these connections are fairly poor as there can be a likelihood of frequent battery removal for whatevwer reason and this eventually disturbs all the connections on the positive terminal, potentially leaving some loose or even broken. I always felt it made more sense to have some kind of insulated buzz bar close to battery where additional cables could be fastened rather than having to fix everything to the positive terminal. Perhaps something like:

http://www.ebay.co.uk/itm/12V-24V-JUNCT ... 2a3a311dc3" onclick="window.open(this.href);return false;

[ermie571]

That's a good idea Covkid! I have something similar. Off the leisure. ..a mini blade fuse box for the radio etc x

Will take pictures of the other end tomorrow. X

[bigherb]

You can fit a ring terminal to the battery cable and use the Durite F0rd converter terminals.

[SamsBus2012]

As an aside, I've been reading this thread as I'm looking to replace the cables on my van (1.9 DG). If you are a bit concerned about all the soldering etc (like me) I have found this company who will make up the leads you want -
Bit pricey I know but if you can afford it and you want the convenience of a bolt on product they may be worth a look. I've dropped them an email to see if they do longer lengths than 3 metres.
http://www.electricalcarservices.com/Ba ... 0-472-2583" onclick="window.open(this.href);return false;

[ermie571]

Useful info....thanks both. Sure I can get the soldering done at my local garage....or a friend if he's not too busy.

Picture of the post in the junction box




And now moving onto the starter...I think I may have some issues here...


Is the cable with the 90 degree rubber? Cover the end of the cable from the battery? Looks like one terminal has given up the ghost.....but there is a smaller cable to the right.....where does that go?



And just for an extra bit of fun looks like I have a water leak to investigate as well....but that's another thread.

So....moving forwards
1. The cable in the junction box has tape on it...,,need to investigate that
2, remove totally the alternator to box connection
3. Is that connection to alternator in thick enough cable?
4. Starter off and a good clean up on all the connections....


Any comments gratefully received

Em
X

[ermie571]

Oh...,back of alternator


And the assistant mechanic....


Lol x

[ermie571]

Oh...its rear wheel steering too hahaha

[CovKid]

Looks like you only have the one cable at junction box. Providing it gets a feed from either the alternator connector or the starter one, it should be fine. I'd start by replacing one from alternator to starter with a new cable, soldered at both ends, then you only have to create a new one from starter to battery. The shortest route for that one is actually inside the vehicle but you need to decide where you want it to run, where holes and grommets need to be drilled etc. Its about 2 metres as the crow flies, and almost four if you go original route.

[bigherb]

VW wired the alternator three different ways for petrol engines.

Air cooled just two parallel cables to the starter no connection to the box at all.

Water cooled is dependant on the alternator fitted.
Alternator to the post in box then to the starter motor.


Alternator to starter then a smaller cable just to supply the post in black box. This looks like your one Em.

[ermie571]

Looks like you only have the one cable at junction box. Providing it gets a feed from either the alternator connector or the starter one, it should be fine. I'd start by replacing one from alternator to starter with a new cable, soldered at both ends, then you only have to create a new one from starter to battery. The shortest route for that one is actually inside the vehicle but you need to decide where you want it to run, where holes and grommets need to be drilled etc. Its about 2 metres as the crow flies, and almost four if you go original route.

thanks again.

so alternator to starter with new cable.You diagram above shows 10mm, so I shall order some of that

starter cable ...hmmm...can't run it inside without removing the interior...so the original route it is. Will order that also.

will also investigate the gear box earth.

Starter coming off tonight for a general scrubbing with the wire brush!!

You mention that there might be a connection to the junction box. The way I read the thread is to leave that present and put another cable directly from alternator to starter.

so starter has 2 wires...the humongous one from the battery (70mm2) and the smaller )10mm2) to the alternator.

is that it for the starter motor?

Will update later - and thanks for continuing support....off to Ebay I go....


Em
xx

Edited - Bigherb - thanks for that diagram....shows the twin wires that Covkid found. I think that is what we may have replaced with the single wire when we tool all the green corrosion off the connection in the junction box. What is the wire marked D+ on the alternator....is this the charge wire??? (the one that lights on the dash when its NOT charging properly)

ta

[ermie571]

When you see it laid out like this, you can see the benefits of moving the starter battery to the engine bay...