Date:         Fri, 3 Dec 2010 02:22:46 +0000
Reply-To:     brett rueff <rueffy@HOTMAIL.COM>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         brett rueff <rueffy@HOTMAIL.COM>
Subject:      91 Vanagon Manual - slow cranking....
Content-Type: text/plain; charset="iso-8859-1"

ok, so I have read the archives and done some diagnosing - im looking for some geniuses out there to tell me im right or that i missed the obvious.

91 Vanagon Manual with subaru EJ22 but stock Vanagon starting system.  Very slow cranking - it has been getting a little bit worse since I got the van a year ago.  It would always start but had a slow crank.  Its getting bad enough now that I need to fix it.

As part of this process I cleaned the battery terminals, removed and cleaned the ground strap and removed and cleaned starter solenoid terminals.

Testing with Voltmeter revealed.

Battery at Rest - 12.57V (after an overnight charge to make sure its full)
Insert Key and turn accessories on (includes headlights) - 11.63V
Cranking measured across battery (+ battery post and - battery post) - 10V

Cranking measured at starter (+ on main solenoid pole - on starter housing) - 8.5-9V

Voltage Drop positive side (+ to pos battery terminal - to solenoid main pole) - 0.2V
Voltage Drop negative side (+ to starter housing - to neg battery terminal) - 1V

So I concluded starter. 8.5-9V should be good enough for a cranking right?  I removed and took it to FLAPS where they bench tested it and said it was fine - I watched the test and it span like mad.  Reinstalled and still slow cranking.  I am ruling out oil viscosity problems as its been about 7 degrees C all week here in lotus land Vancouver BC.

I can only guess its still the starter and its laboring under the load of the engine.  I read in the archives the bushing on the end of the starter wears and causes hard cranking.  Based on my testing that is all I can figure is the problem.  Suggestions before I pull the thing apart again?

Thank you gang.  Will post to the vanaru list as well.
brett