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Date:         Sat, 19 Feb 2011 13:38:06 -0500
Reply-To:     Larry Alofs <lalofs@GMAIL.COM>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Larry Alofs <lalofs@GMAIL.COM>
Subject:      Re: Advice-New Ignition Switch/Cig Lighter/Fan Switch
Comments: To: Michael Sullivan <sandwichhead@gmail.com>
In-Reply-To:  <AANLkTinV6uM5XNUYzSEHTFF55hJy2FBREHsVxL9ofDp2@mail.gmail.com>
Content-Type: text/plain; charset=ISO-8859-1

Michael, On a '91 I would expect the main cable from the battery to the starter to be of adequate diameter. VW upgraded it for the later model years. Corrosion at the ends of the cable can be a problem especially at the battery. You might cut back the insulation a little and check for green or white deposits.

Many people lump two starter/cranking problems together and therefore are not clear about which remedy to use:

1. Starter engages when the key is turned, but turns the engine too slowly. Here poor cables and/or ground connections can be the cause and well as low battery or bad starter.

2. There is no sound when the key is turned (other than the fuel pump). Here the ignition switch is one of the usual suspects as well as any wires and connections between the switch and the push-on terminal on the solenoid. Some say that a gummed up solenoid can also contribute. A "hard-start relay" is very often effective in solving this problem, unless the brushes, etc. in the starter are pretty bad. The ground path for the solenoid is thru the starter. I feel that if the relays were installed proactively, a lot of ignition switches could be saved. I believe that I measured the current in that circuit as something like 37 amps. That is an unreasonable amount for those switch contacts. Headlight relays should also be installed for similar reasons.

Hope this helps, Larry A.

On Sat, Feb 19, 2011 at 12:25 PM, Michael Sullivan <sandwichhead@gmail.com> wrote: > Just wanted some advice before I start on these chores. > Symptom-Slow cranking/no cranking new starter and battery drain and ignition > switch going out. > > I am going to check the grounds from alt to chassis and from tranny to > chassis.  I wanted to run new battery cable to alt, but Bently says you have > to remove the gas tank to do this properly.  Is this true? > > Ignition switch-pg 94.2....Is this the only way to go about this?  Fig 2 > needs a special tool. (I got two of these switchesso I will have a backup). > > Fan switch in dash.  Speed 3 does not work unless I lightly touch the > switch.  I got a new one and need to know if this can be checked/replaced > without removing the dash? > > Lastly, I got a new cigarette lighter socket(with green illumination).  Mine > is a little loose.  Can this be done without removing the dash? > > Well, that's it.  It's raining so I cannot work on the grounds today, but > thought I would take the main battery out and have it checked while I work > on the switches today inside the van. I appreciate any advice. > Thanks. > > Michael in San Antonio > 91GL Weekender AT 2.1L 'Gringo' >


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