Date: Wed, 12 Apr 2000 19:55:52 EDT
Reply-To: FrankGRUN@AOL.COM
Sender: Vanagon Mailing List <vanagon@gerry.vanagon.com>
From: Frank Grunthaner <FrankGRUN@AOL.COM>
Subject: Re: 1982 Diesel Intermittent Start Problem (extensive experience)
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Got to weigh in here.
My Diesel/now GTi Westfalia Vanagon and I have been together since 14 miles
were on the odometer and it was delivered to me in July of 1982 in
Weidenbruck. The number of starters this beast has eaten would make a
substantial pile next to the garage. The first two were replaced under
warranty. Although I am writing this without access to my records, the
average time between replacements runs about 1 year and ranges from 9 months
to 14 months. New or rebuilt - statistically insignificant. Identity of
rebuilder - Bosch, Autolight, Herbie's Super Starter Service --- only the
cost varies.
Oh yes, I have replaced the starter switch twice, once on warranty, once by
myself. No impact on the statistics. More than 5 years ago, I added a heavy
duty solenoid right next to the starter and long ago I rewired the van with
number 2 gauge wire from the battery to the front fuse box, from the battery
to starter and solenoid, number 8 wire from the starter switch to the
intermediate solenoid, and number 4 wire to the starter solenoid from the
intermediate solenoid. I have added heat shields to safeguard the starter
from undue thermal stress. I have even argued to the wife that I changed out
the diesel and put in the 1.8 L 8V GTi gasoline engine to reduce the stress
on the starter (compression difference)! Interesting dismissive expressions
generated by wives, BTW.
In all of this only two things have reminded me of the inexorable passage of
time: taxes and Vanagon starter replacement. When we purchased our Ford
Expedition (wife's car) I was in panic that it couldn't be obtained (at that
time) with manual transmission. How will we be able to start it when the
starter fails? I asked the salesman.
With new modification, I remain convinced that I have now defeated the
starter eating monster. However, when I am least prepared (too painful to
relate) I again encounter the dead key syndrome. Saturated with wifely abuse
about the reliability of this machine (I try to tell her its only an
engineering prototype) I again try to trouble shoot the problem. Initially,
after the perfunctory drift start, the problem won't reoccur for 10 or more
starting episodes, then 1 in 5 finally 10 to 1. Nonreproducibility has been
directly related to the availability of time and test equipment. Generally,
DVM in hand, remote starter switch and Vanagon in air, I will find that the
starter terminal shows 12 volts to ground and no spin!. Replace starter, 0.25
volts to ground and starter spinning!
After taking the starter off and testing again, it often reads a fraction of
an ohm to case ground. (It was open on the engine). Looking at the brushes
and the commutator, one sees one or more burned segments.
So: 1) I always keep a spare starter. I have gone to Autolight rebuilds
because the foolishly offer a lifetime warranty. Haven't paid for the last
three starters. Typical personnel turnover at my local Flaps, minimizes the
chance encounter with a counterman with gifted memory.
2) I have brought a set of taps out to a switchable voltmeter (same one
used by Darrell in the Digitool. One line monitors the voltage at the
ignition switch addressable terminal, the second measures the voltage at the
starter solenoid, a third monitors the voltage at the starter power terminal,
a fourth measures the voltage drop across the line from switch to starter, a
fifth measures the voltage drop from power terminal on the starter to the
starter case.
Just waiting for this SOB to fail again.
To summarize, my general key failure is always repaired by starter
replacement. I claim nearly 19 replacements. After each replacement, no
subsequent failure for at least 6 months. Appears to be a burning of internal
contacts caused by ... I don't know. The starter is always dry, never
covered in oil. It is always tightly bolted down. Often, poor contacts have
seemed to be a problem at the starter, but by the time of repeated failure,
the starter has been damaged. Alistair Bell and I have gone around about this
and his experience is different.
Caveat: I am only discussing the original issue Diesel Vanagon manual trans
starter. Diesel or gas engine, no difference.
Advice: Buy rebuilt starter from local Flaps. Buy the least expensive one
that comes with a lifetime warranty. Buy two and pay the core charge if they
have a foolish special. Next practice .. under the car, release the case
bolts, undo the clutch locator bar, off with the power leads (you remembered
to disconnect the battery, right), rotate to clear clutch slave mount, down
with the old, in with the new. Usually takes 15 to 20 minutes. Longer if
raining, much longer if wife has some comments to make (often decidedly
unconstructive).
Sorry for the length. Had considered an entry for the sticker contest in
which an outline of the starter with the international null symbol would be
the graphic highlight, but the wife thought it was too subtle.
Hope this helps other victims.
Frank Grunthaner
