Club 80-90 Forums

It never rains but it pours.
Wife aborted her camping trip yesterday when hot start problem reappeared after she filled up at the petrol station.
Said she can't trust it so not using it. She's due to go again Monday, but say's she's not using it any more.
So, I decided to clean all the contacts on the starter and solenoid and found the braided wire from solenoid to starter very frayed. So much so that in trying to clean the contact on it, it broke off completely.
So,
1. Am I stuffed with that starter, without access to heavy duty soldering equipment ?
2. Anyone know a supplier who might be able to do a next-day on a replacement starter ?
3. Anyone know the correct part number to search for ?
Its a 1983 2.0L air-cooled, manual.
Doesn't look like Heritage/Brickwerks/JustKampers have them.
Cheers.

Looks like Eurocarparts have starter motors listed and in stock for 1982 2.0L petrol, but not 1983.
Are starters the same for 1982 and 1983 2.0L Aircooled manual ?
They don't even allow you to select 2.0L engine for 1983 van, so I usually choose 1982 to find parts.

You can use the later petrol WBX starter motors, the only difference is they have a longer battery cable mounting stud

Dont forget to change the oilite bush.

You wont find a listing for 83 because that's the year the water boxer engines came in.

OK. Have ordered 1982 one from ECP.
Fingers crossed.
Cheers.

OK. So picking up new starter in the morning.
Trying to get the old starter out and was struggling to get a socket or spanner on the top "bolt" so took a photo, and it turns out it's not a normal bolt at all, it's some weird D-shaped thing.
With the limited access I'm struggling to get any kind of tool on it.
Has anyone got any idea what this is, why it might have been used, and most importantly, how on early I'm going to get it out.
Praying it's not a gearbox or engine out job just for starter motor

Have a look on the other side of the bolt..... you may find a nut

The D shaped head is self locking against the starter motor body you only need to undo the nut on the engine side.

Oh dear. Now I do feel stupid.
I thought it was just a bolt with thread inside the casing.
Will give it another go in the morning

Just remove the air filter and you will see it.

Some helpful pictures here, including replacing the bush

https://aircooledvwt25.wordpress.com/20 ... ter-motor/

I have never had to replace the starter bush (I have an auto) But I have read many times its best to soak it in oil overnight.

Yep.
Confirmed my stupidity.
I was assuming bolt was removable from underneath, but as mentioned, its easily accessed by removing the air filter.
Starter replaced, and back on the road. It was only £96 from eurocarparts, so only time will tell how good it is, but I needed whatever I could get ASAP.
Van is still not the easiest to start when hot, but at least i've ruled out starter motor and connections in that respect, so will have to start looking for other possibilities for that.
Cheers.

Just hold the throttle fully down (don't pump it) and crank the engine till it starts. The heat rises into the carbs and vapourises the fuel leading to a rich mixture which you have to purge.