fixing starter solenoid cable (1,6 D NA)

[epowell]

Hi Diesel Folks

I'm trying to get my Vancouver Diesel started, and think that I have isolated the problem.... Or at the very least, THIS is part of the problem and I don't know what to do about it.

The cable from the solenoid to the starter is toast. Any suggestions on what to do? I still seems to be well attached to the starter, but that cable came unattached to that "L" shaped connector piece which attaches it to the solenoid.

Thanks
Ed

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www.edwardpowell.com

[Gnarlodious]

Are you talking about the plastic covered female spade connector that fires the solenoid? Yeah that pops off if its not secured. I have a spring that applies tension and keeps it on. For me it has popped of at the most inopportune times and then you can’t crank.

Oh now I see what you mean, the braided copper cable into the motor. Did it break off?
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Vanagon ’83 diesel AAZ w/Giles injection, 5spd 4.57R&P+TBD and a '78 diesel Rabbit

[epowell]

[Gnarlodious]

I hate to say it but it seems likely you will need a new starter sometime soon anyway. I recommend scrapping that big old thing and installing the new improved model SR28X starter featuring gear reduction. It will spin faster, pull less power and be easier on your flywheel. Plus, because it is smaller and lighter, it will be way easier to install and remove.

Chances are that copper braid is corroded away and I don’t know what it attaches onto but you could be wasting your time. Sure you could take it out and go to all the trouble but I wouldn’t bother with that old boat anchor.
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Vanagon ’83 diesel AAZ w/Giles injection, 5spd 4.57R&P+TBD and a '78 diesel Rabbit

[epowell]

I hear ya... Thanks for the recommendation (SR28X starter)... looking for one, but can't seem to locate here in Canada. Amazon out of stock.

The braded wire looks OK, but zooming in on the fotos looks like it is also starting to pull off slightly from it's connection to the motor... ...if I attempt a solder repair perhaps I will need to solder a little bit on that end too.

I am only here in Vancouver for another 10 days so there is no hurry to locate a new starter since I won't be back again until next year... HOWEVER, my goal right now is at least to START UP the van at least once while I am here. I have not started her up since last year, and seems not a good idea to leave it ANOTHER year without starting up.

So I will keep looking for a new starter, but also attempt a ghetto-fix on this one at least in the hopes of starting up the van.

I am aware that this is a HIGH VOLTAGE un-fused wire that must be heavily shielded against contact with anything else.

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www.edwardpowell.com

[MarkWard]

Looks like you could crimp a heavy duty eyelet on the solenoid end and reattach for now. Would be easier with the starter on the bench.
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☮️

[epowell]

[old_man]

Alternative idea: Buy a TDI adapter from T3Technique and then get a TDI starter from the junk yard.

[epowell]

...so as I said, I really wanted to get Toni running a bit before I head back to Europe.
So I managed to pull the starter and do the ghetto fix with some hardware things I found in my mom's basement here.... and.... it worked!!!!

I think this starter itself is still pretty OK, but that braided cable will not last so much longer... it is very compromised where it attaches to the motor. I would ultimately just like to completely REPLACE that braided cable > I wonder how that could be done.

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www.edwardpowell.com

[T3messie]

Well done Ed,

look for Bosch 1 004 336 621. I never had luck trying to solder that corroded cable.
The brushes may be replaced anyway.

[epowell]

[T3messie]

https://www.google.com/search?channel=fs&client=ubuntu&q=Bosch+1+004+336+621

[Igeo]

It seems a bit of a weird design to have that uninsulated conductor exposed like that in the first place.
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1987 Westfalia 2.1 WBX Manual

[epowell]