Date: Thu, 3 Jul 2014 01:32:31 +0000
Reply-To: Richard Golen <rgolen@HOTMAIL.COM>
Sender: Vanagon Mailing List <vanagon@gerry.vanagon.com>
From: Richard Golen <rgolen@HOTMAIL.COM>
Subject: $100 Reward to Solve Starter Problem
Content-Type: text/plain; charset="iso-8859-1"
Dear Vanagon List Members,
I am offering a $100 Reward for the solution to my starter problem. Please
read all of this carefully before suggesting your solution. The reward will be
sent via PayPal or via check.
The
"patient" is a 1987 Vanagon Westfalia with a manual transmission. The
"problem" starter solenoid will not disengage when key released from
"start" position. Sometimes, I can quickly switch off and back off
and the starter will briefly disengage, but will re-engage.
Here's what I have observed. On a trip to Lime Rock Park two
weeks ago, while on the interstate, smoke and electrical wire burning smell
started coming out of the area under the rear seat in the area of the ECU. I
quickly shut off the engine, coasted to the breakdown lane. Popped the rear
seat and the cover to the ECU to see if the problem was, in fact, the ECU. The
only thing I noticed was the cooling fins on the ECU seemed to be hot. I let it
cool down, restarted the engine, and drove off. No problems the rest of the
trip to Lime Rock.
Two days later when we were leaving LRP, I started the
engine and the revs went from 800 to 1500 to 2000 to 2500. Blipped the
throttle, no change. Shut off the engine, and checked the engine. Throttle and
cable were not binding. I disconnected the idle stabilizer and the revs dropped
to 800. While checking things out, I noticed that one of the wires from the
power steering sensor had come loose and grounded out. Taped the connector so
it wouldn't ground out again on the way home.
The next day I installed a new Bosch rebuilt starter. I had
planned on replacing the starter as it was getting old. The new starter worked
perfectly. However, the next morning when I started the van the starter would
not disengage. Shut off the ignition, turn it back to on, engine was running
but the starter did not disengage. I did
put the old starter back in, and it too was doing the same thing. Put new
starter back in.
Here's what I've done so far:
1. replaced the ignition switch. Still same problem.
2. made a jumper for the ignition switch plug with 4 male
terminals. One terminal to the + from the battery, one to the fuel pump side of
the switch, one to the ignition (warning lights came on with this), then I
jumped the wire to the starter solenoid. Engine started, disconnected wire.
Engine ran, but starter did not disengage.
Tried it again. Starter did not disengage when I
disconnected the starter wire. This time, I disconnected the fuel pump wire and
the starter disengaged. With my multimeter, I checked the voltage at the
solenoid. No voltage with the switch off. With the switch on, but not to start,
power to the solenoid. Disconnected the fuel pump wire at the ignition plug,
and the power to the solenoid lead went off...no voltage.
3. Disconnected the auxiliary battery and auxiliary battery
relay. No change.
4. Checked the wiring harness in the engine compartment that
contains the leads to the power steering sensor and the plug to the idle
stabilizer. The power lead wire to the sensor had grounded out, heated up and
melted its insulation as well as some of the insulation to the power lead to
the stabilizer.
I figured voila! Found the problem. Repaired the wire to the
stabilizer, put in a new section of wire for the power steering switch. Started
the engine, and starter would not disengage.
5. Swapped out the idle sensor relay. No change.
6. I removed the ECU and popped the cover. I couldn't see
anything that looked burned.
I've poured over wiring diagrams in the Bentley as well as
some that are online and am at a loss. The only other potential part that could
be remotely related to this issue is the ECU. I have a spare one coming in the
next few days, but don't want to put it in until I'm sure I'm not going to
damage it.
The only option I see is to run a new wire from the ignition
switch to the solenoid, perhaps using a relay.
So, here's the challenge. What could be the problem? I will
pay $100 to the person who is able to diagnose the problem and I can get the
starter to work properly. I will be more than happy to provide more info or
answer any questions.
Thanks in advance.
Ric
87 Westfalia
|