Date:         Mon, 5 Mar 2001 10:32:01 -0600
Reply-To:     Larry Alofs <lalofs@ENTERACT.COM>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Larry Alofs <lalofs@ENTERACT.COM>
Subject:      Re: Intermittent Starting problem
Comments: To: Barry Armitage <armitage.1@OSU.EDU>
Content-Type: text/plain; charset=us-ascii

Barry Armitage wrote:

>  on my last long trip I
> stopped at a rest stop and the car wouldn't start -- lights okay, no
> clicking, no turnover of the starter or the engine.  I push started it and
> it was okay, and I finished the trip.  For the next few days it would do
> the same thing almost everytime I tried to start it (I learned to park on a
> hill).  Then after a few days the problem went away and the van has been
> starting fine, everytime for the past month.

Barry:
I've had 4 VW vans with the same problem, starter inoperative after 2 hrs at
speed on a trip (no problem around town).  Because of the voltage drop in the
long wire from the ignition switch to the starter solenoid the voltage
delivered is just enough to activate the solenoid when everything is in good
condition.  In time, the contacts in the switch,etc. deteriorate and the
brushes in the starter itself wear, providing a poor ground path for the
solenoid.  The brushes and the solenoid have more resistance when hot.  Tapping
the starter or solenoid with a hammer or lug wrench while a helper holds the
key in the start position will usually get you going (only option when on a
trip with an automatic).
  On 3 of my vans the solution was to install a relay under the back seat.
(Current from ignition switch activates relay; relay connects solenoid to
plus.)
  On one vehicle, the relay only helped temporarily.  Having the starter
rebuilt fixed it; the solenoid ground is thru the starter.
Good luck.

Larry A.
Chicago
91 GL  (my 5th)