Date:         Mon, 12 May 2003 15:04:45 -0400
Reply-To:     Vanagon man <vgonman@MSN.COM>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Vanagon man <vgonman@MSN.COM>
Subject:      Re: 87 GL Intermittantly Not Starting
Comments: To: mark drillock <drillock@EARTHLINK.NET>
Content-Type: text/plain; charset="iso-8859-1"

> That is not a valid assumption about the ignition switch. The switch has
> multiple contacts inside it that make the connections for different
> functions. One can fail or be flaky while the other contacts work fine.
> The one that runs the starter is not the same one that causes the fuel
> pump to run for a few seconds. I try to keep a new ignition switch (and
> a headlight switch) in the glove box of Vanagons that I use on trips.
> These things fail eventually plus it is very quick and easy to prove
> that it is or is not the switch.
>
> It is a simple matter to get a new switch and connect it to the wires
> without actually installing it in the steering column. New switches are
> ~$15 and easy to find as so many VW cars use the same one. Remove the 2
> screws holding the bottom cover onto the steering column. Then unplug
> the connector from the ignition switch and plug it into the new one. Use
> a screwdriver to operate the new switch. You still need the key to
> unlock the steering if you want to drive the van.
>
>

This a good test to verify switch failure.  But, in my discoveries, quite
often the wire that is red with a black stripe that comes out of the
connector to the ignition switch and goes back to the starter solenoid is
worn out, giving these intermittent signals.  Here is how i diagnose both.

If the key is engaged and all you hear is a fuel pump, i pull the connector
off the ignition switch and jumper between the 10g red wire (from battery)
and the red with a black stripe(to starter solenoid) if starter turns, bad
switch.  if starter does not turn further testing is necessary.

Test red wire for voltage in plug.should always have 12v or more.  If good
voltage do the following.

I go under the van and take the red with black stripe wire off the solenoid,
and run a new 10g wire from the solenoid, and just dangle it thru the
sliding door, up to the steering column (for testing purposes, remember) and
strip 1/3" or so off the end of it.  I put connector back on ignition switch
and touch the new wire to battery + ...........usually starts right up.  If
this is the case, then you need to install this wire more permanently under
the van, and up the steering column.................replace the old wire
with the new one, being sure you have solid connections.  Be sure you use
all new wire, do not splice into the old wire.........or you will be back in
the same situation in the future.