Starting problem

[mark1967]

Back end of last year the starter on the van finally gave in so I replaced it with a new one from GSF,round about the same time I changed the battery (also for a new one) as well as a new ignition switch.Even with all this starting was what can only be described as iffy. After not being used for a couple of months it just doesnt want to turn over at all now.
Yes I charged the battery fully,I even swapped it for a known good battery with the same result.Thinking it may be the main lead from the battery to the starter I temporarily added an extra an cable to "help it along" a bit.This made no difference either.The only thing it does do is make a bit of a clunk from the solenoid when you let go of the key.In my best attempt to be technical I coupled a multimeter between the big terminal on the starter and earth.This read a healthy 12.5volts,until that is i turned the key and the voltage dropped to zero
Any suggestions for the next thing to try ?

[ewenmaclean]

Hello,

have you checked the earth straps on the nose of the gearbox and the one in the engine bay (if there is one), and the earthing of the neutral battery connection? They are always worth checking and making the connections good.

Not sure I understand well enough the multimeter test you did, but I'm sure someone else will...

Ewen

[mark1967]

Hello,

have you checked the earth straps on the nose of the gearbox and the one in the engine bay ?

Yes both have been replaced with new. Like I said I`m at a bit of a loss as I`m running out of things to swap

[ewenmaclean]

Hi,

I'm probably asking stupid questions, but maybe worth it. Can you push start the van ok, and if so does that make any difference? Did you replace the starter motor bush? I wonder also whether possibly the solenoid itself could be shorting before the current gets to the starter - not sure that's possible, but mine once got stuck closed, which was really annoying and a massive fire hazard. The connections to the starter via the load reduction relay might be worth checing I suppose but I very much doubt that's the problem if you can hear the solenoid clicking.

Hope you find the problem

Ewen

[mark1967]

Yep changed it when I changed the starter.And it will start with a shove

load reduction relay

Wheres that live? When I say you can hear the solenoid it is only just audible not a healthy clicking like when you have a flat battery

[ewenmaclean]

Hello,

it's a bit of long shot - I'm afraid I don't have my van at the moment, or my wiring diagrams, but the load reduction relay sits in the relay box and takes a signal from the ignition "X" contact, and diverts all power to the starter solenoid and the lights, and switches everything off. I just wondered if you might have a slightly weak connection to the solenoid itself via that, but like I say I don't have my diagrams. From memory it's a thick white and red wire which goes to relay position 8 - I *think* it's got number 18 printed on it....

sorry you still have problems and hope you get it sorted soon

Ewen

[mark1967]

Thanks mate,will have another peek at it at the weekend. (work all week )

[ewenmaclean]

Hello again,

I have to apologise - I don't have my books so couldn't look at my books, but got the X-relay wiring wrong - the red/black wire from the ignition is the one you want to look at. Sorry about that - my mistake ...

Ewen

[tonytech]

Did you clean up the earthing strap to body connections?
It is always worth rubbing down to shiny metal, particularly the battery one.
also worth a look is the +ve battery lead. the cable into the terminal clamp can go fuzzy.

Your multimeter test shows that when drawing a large current there is a large (more than a few ohms) resistance between the battery and the starter.

T

[fairwynds]

... my problem was the BATTERY earth strap. Removed it, cleaning it up with drill/brushy thing, cleaned battery terminal with emery paper, sanded the bodywork where it fits to shiny metal, refitted strap with new bolt and washer - 'NoCrode' smeared on (or use Vaseline) and hey presto! years of lazy staring cured.
It seems the problem was the moisture working its way up into the threaded hole from the wheelarch, resulting in rust buildup.
VW used the threaded hole as the actual earthing contact point (ie, the flat surface of the bodywork was painted) so sanding that paint off is a belt and braces cure......

Let us know.. FW