Date:         Sun, 15 Apr 2012 13:29:47 -0700
Reply-To:     BenT Syncro <syncro@GMAIL.COM>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         BenT Syncro <syncro@GMAIL.COM>
Subject:      Installing adapter for TDI Starter on Auto trans Vanagon
Content-Type: text/plain; charset=us-ascii

It's been a bit of an ordeal getting the correct starter for the adapter because I had two vendors sell me the wrong TDI starter. What made it worse was the used starter P/N marking was partially scratched off on the ones I got.


Thought I'd post this info for others who might run into the same predicament. 

0 001 125 012  (013)  correct
0 001 121 022  (023)  incorrect 

02A  911 023 R            correct
02M 911 023               incorrect 

The incorrect starter identified above are for a 2004-later manual trans TDI. The correct one is from a 1996-2003 manual trans TDI.

There is a slight difference in length. But the problem is the bolt patterns are not the same. As luck would have it, the  letter 'M' was badly scratched up on the starter I got. I am not sure about the significance of the 'R'. Without that 'M' and a vendor swearing it was for an '03 TDI, I spun my wheels trying to figure out why it would not fit. It's clear now.

So we start bolting everything up today. Then [B00M!] another snag. The fellow who worked on the starter last time, substituted a hex head for the upper bolt. The head would not clear. Now I have to hunt down a hex head bolt longer than a cigar -- on Sunday!

Also noted that the connector on the main harness on the Vanagon is designed for a very long stud on the original Vanagon starter. Guess this means some cutting and crimping will be in order. I dread replacing it with a less sturdy terminal end but cannot see any way to connect to the shorter TDI terminal stud.

Foiled again. Getting back to this tomorrow or the next.:-(


BenT
sent from my electronic leash