Date:         Fri, 25 Apr 2003 12:38:01 -0700
Reply-To:     mark drillock <drillock@EARTHLINK.NET>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         mark drillock <drillock@EARTHLINK.NET>
Subject:      Re: occasionally won't start.
Comments: To: Tim Demarest <tim.demarest@POBOX.COM>
Content-Type: text/plain; charset=us-ascii

This area of the wiring is more trouble prone as these vehicles age. The
stud in question is the connection point for all the +12 volts used by
the ECU, injectors, and fuel pump, namely all the heavy current users in
the engine compartment. VW changed the wiring to this stud several
times. I have seen failures in every variation. Intermittent stalling
and failure to start is a common symptom. When I cruise junkyards for
Vanagon parts I see burn spots and melted areas frequently in these
wires. I think many Vanagons are sent to their graves because these
intermittent problems drive the owners over the edge. I have helped
numerous Syncro owners with these wiring related problems and I used to
wonder if they were somehow more susceptible. I now think that Syncro
owners are just less inclined to junk or sell one with these problems
and make more of an effort to track them down.

Mark

Tim Demarest wrote:
>
> I had a similar problem with my '85 right after I bought it (I mean right
> after, I got it home, and then it wouldn't start again). It would crank
> like a champ, but wouldn't kick over.
>
> It turned out to be a bad (undersized, under-crimped and old) splice in the
> smaller wire leading from the starter. This wire feeds everything in the
> engine compartment *except* the starter. Open the black box on the firewall
> (on the left side, as you stand behind the engine compartment scratching
> your head). Inside, you will find a stud with some big red wires going to
> it. With the key on (but not cranking) you should see 12 volts there. I was
> getting something like 5.
>
> I connected my jumper cable from the positive battery lead to that point,
> and she started right up.
> ....