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Electrical... <Shudder>
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MNThingGirl
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Joined: April 08, 2004
Posts: 6
Location: MN - Of course
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PostPosted: Tue Jul 13, 2004 9:51 am    Post subject: Electrical... <Shudder> Reply with quote

So.... Brand new, fully charged battery. Clean connections. Turn the key one step, Oil light goes on bright and steady. Turn the key to Start and "Click", nothin'.
Here's the kicker... Only happens once in awhile. Every third for fourth start. Can't find a rhyme or reason for it and jumping it or popping the clutch starts her right up again. All the wiring under the dash looks good and the engine compartment.
Suggestions??
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bljones
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Joined: February 08, 2002
Posts: 2377
Location: ontario canada
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PostPosted: Tue Jul 13, 2004 10:04 am    Post subject: Reply with quote

sounds like the starter solenoid is hanging up, or getting inadequate power. slide underneath and do a quick clean of the connections at the starter, and check your grounds to make sure they are all clean. If the problem persists, it's time to R&R the starter.
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Andromeda451
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Joined: July 18, 2004
Posts: 4
Location: Queen Creek, AZ
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PostPosted: Sun Jul 18, 2004 1:01 pm    Post subject: No problem Reply with quote

M,

The starter problem you're seeing is common on all VWs up to and including late '80s cars. This assumes the starter is OK, which in my experience is 99% of the time. The fix is straightforward: Clean every connection on the battery and starter. That means removal, sandpaper or abrade to bright metal and replace each connection. The ground wires get the same treatment. Under your Thing on the left motor support horn towards the front of the unit should be a groundstrap. That strap needs to be removed and connections cleaned then replaced. I use star washers on each connection when replacing to make sure there's good metal to metal BITE. This assures good connectivity. Last I add a 30Amp 12VDC relay from radio shack in the starter circuit. The part number is 275-226. To install:

Remove the small wire that comes from the key to the starter motor and install that connection to terminal 85 on the relay.
Terminal 86 on the relay goes to chassis ground. Now if you switch the key to start the relay will click.
Terminal 87 gets wired to the Large battery lead at the start solenoid.
Terminal 30/51 goes from the relay to the small spade lug on the solenoid that originally had the key lead installed.

What you've done here is installed a relay to remove all voltage drops from the 30 year old wiring in the 181 and made sure the starter solenoid gets the full 12V it needs to operate properly. I've done this treatment to rabbits, bugs and things with 100% excellent results.

good luck.
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Andromeda451
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