Diesel Vanagon starter - replace or rebuild?

[Country Doc1]

Hi to all, thanks in advance for any advice!

I have an 89 factory TD Vanagon that now has a 1.9AAZ, and the starter clutch drive is starting to slip when it's hot. I have had some people tell me that the rebuilds use aftermarket clutch drives which fail within a few years, and that it's better to rebuild the original Bosch one.

I also spoke to a rebuilder in the Finger Lakes area who recommended consider a Mahle starter instead of a rebuild, as a direct replacement option, but I can't find any reference to a Mahle starter that is a compatible fit?

For reference, the PN he suggested was Mahle MAH-MS285.

Thanks!
dc

[crazyvwvanman]

https://www.summitracing.com/parts/mah-ms285

[Country Doc1]

Yes, that's the only internet page I could find - I'm just not sure it would actually work, given that I can't find any reference to it on thesamba or other Vanagon places? (The starter shop seemed to think it would).

[crazyvwvanman]

https://partinfo.org/mahle-original-ms285/

[Sodo]

While you're under the van, optimizing....
it's a good time to ALSO delete that satanic front transaxle ground strap
and upgrade to a proper eqpt ground from the starter case to the chassis.

Someone told me the diesel bolt head is in a recess and to do this you need to procure a longer bolt+spacer. I've never seen a diesel starter bolt.
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'90 Westy EJ25, 2Peloquins, 3knobs, pressure-oiled GT mainshaft, filtered, cooled gearbox
'87 Tintop w 47k 53k, '12 SmallCar EJ25, cooled filtered gearbox
....KTMs, GasGas, SPOT mtb

[Country Doc1]

Ah, thanks! That looks like the Mahle would fit. The rebuilder felt it was a better option than the reman Bosch ones - maybe I'll go that way.

Thanks for the tip on the ground strap

dc

[crazyvwvanman]

Diesels are different. The two 19mm headed starter bolts are not a great place to add a ground over to the chassis.
Other spots are better IMHO.

I've replaced a bunch of diesel van starters but have never run into a Mahle branded one.
It seems lots of old big "names" now sell asian parts so I'd hesitate to pay much for the Mahle without knowing where the current supply comes from.
You can buy new diesel starters from asia for $75+ and they seem to last as well as some rebuilt ones.

Mark

[Gnarlodious]

Good time to upgrade to the SR28X gear reduction starter. It'll cost more but be way better. It is smaller so easier to install, and less heavy so you won't bash your brains in if you drop it on your face. I put in a Genuwine new Bosch starter in 2008 and it is still going strong. Worth every dollar.
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Vanagon ’83 diesel AAZ w/Giles injection, 5spd 4.57R&P+TBD and a '78 diesel Rabbit

[ALIKA T3]

[valvecovergasket]

i just went through this on our tdi swapped van

it had the original starter, i took it to my local rebuilders and they decided itd be easier to replace with a new bosch unit

it was bosch part number 001 110 009
its smaller than the really big original starter, and appeared to not be too exotic or tough to get since they only charged me something like $130 for it.

i looked into the tdi swaps but it seemed like the juice wasnt worth the squeeze considering how cheap this one was.
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MegaSquirt resource - SpitfireEFI.com

gone, but not forgotten: '83 tdi westy - swap thread

[ALIKA T3]

Looks like it was used until recently on Polaris machines. Interesting!
Found them rebuilt only though.

https://www.motorcityreman.com/booe00st1.html

[valvecovergasket]

Granted, I haven't started the van yet as I'm wrapping up a suspension and brake refresh but it sure popped into the stock spot like it was meant to go there.
And I trust these guys they've been really good with oddball custom stuff and all they do is alternators and starters.
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MegaSquirt resource - SpitfireEFI.com

gone, but not forgotten: '83 tdi westy - swap thread

[westyventures]

Ditch the antiquated starter and upgrade to the TDI starter, using the adaptor plate available from T3 Technique. Self-supporting nose too so no more interference issues with larger clutch setups including the dual-mass.

[Country Doc1]

Thanks Karl, unfortunately missed this post before ordering the Bosch SR28X.

[crazyvwvanman]

Hopefully the SR28X you receive will be the newer type gear reduction version.
Bosch ships large older type and compact newer type under the same rebuild number.

Mark