Earthing problems I think?

[Oldiebut goodie]

 

The crazy bit is the earth strap / negative battery cable getting hot. That defies all logic. Especially in my simple little mind.

Perfectly logical.Everything that is powered by the positive side of the battery completes the circuit via the negative, If the negative is high resistance to chassis it will get hot. Not difficult to fathom out! Worse if someone has put an undersized earth strap instead of the original.

[Robsey]

Indeed - I left myself open for that one.

I made the silly assumption that if the earth cable had been replaced, then it would be one sold for the purpose by someone like Brickwerks etc.

Although looking at the schematics.
(VW / Haynes and Bentley).

The battery to starter is listed as 70mm CSA.
Battery to fusebox is 6mm
Fusebox back to starter solenoid is 6mm

And then the ground strip is listed at only 25mm csa.

Hmmm - maybe the design is wrong.

76mm going out (+)
25mm return (-).

And that excludes anything else from the fusebox that isn't disengaged by the X relief relay.

Sheesh!!

Of course the 70mm csa is to overcome voltage drop, rather than current carrying capacity.

[69gp225]

Hello,

I actually bought my replacement negative battery cable from brickwoks. It’s 35mm with 8mm ring terminal. Looks like the correct length.

Would this be acceptable to use?

Couldn’t find a brass exact copy of the original

Thanks

[Robsey]

Yes - the Brickwerks cable will be perfect for the job.

it exceeds the current carrying capacity of the original VW specification.

[69gp225]

Hello

My new starter turned up and looks very similar but when trying to fit it the pinion shaft that goes into the bush was a fraction bigger than the old starter I used?
So it wouldn’t fit.

Are there two different sizes shafts?, I thought I ordered the correct one for a petrol DG engine.

Can anyone help, I’m sending it back as it had damage to the rear bolt. So need to order the correct type.

Thanks

[69gp225]

It wasn’t only a fracture bigger in diameter but looked a little longer.

Thanks

[Robsey]

Is it an auto, or manual?

I looked at the Brickwerks website, and there appears to be only one option for a waterboxer manual.

Autos is a different story as they look very similar to the 2.0 air-cooled. So probably a potential of three very similar looking units.
2.0 CU.
Waterboxer auto upto 81
Waterboxer auto from 81.

Diesel is the only starter with a shroud on one side of the starter pinion.

As you can tell, I am no expert, but just an observation.

[69gp225]

Thanks mate I’m going to have my old u it repaired to save all the hassle thanks

[69gp225]

Well after all these months I finally got time to fit a new starter. I’ve recently cleaned all the terminals. Have a new control module and relay in the front passenger fuse box fitted. Van has been sitting for a while. All I’m getting is a clicking noise from a brand new starter and the click is also in the black box in engine bay.

I’ve ordered a new relay which goes in the black box.

Would I still see a spark from a plug across the casing of the engine with only a click?
I’m wondering if it could be the coil?

Truly sorry I’m resurrecting this but my time has been spent restoring a classic car and the van will probably have to go at some point. Really want to get it running.

Hope you can help. Thanks