Dead Starter (help boshman)

Over the last three months the starter has become increasingly more difficult to engage. When turned there was no response. With several tries and more pressure applied the starter would engage. The battery is charged and the connections are clean. I am new to VW engines and need help trouble shooting.Connected to both poles of battery is a black box approx 2x5 inches part #357 919 506 with a clear window and two half inch bolts on top. What is this? 1995 V-6 Is there a way to test starter without removing? Is the switch connected to a fuse? Any help would be appreciated.

I believe that is the fan control module. There are a couple of things you can do to check out the starter. If you don't have a heavy gauge remote switch you can sacrifice a screwdriver to jumper across the two large terminals on the starter solenoid (be sure it is in neutral if this is a manual) and the starter motor should engage. If the motor seems okay you can use a test light to see if the trigger wire (small red/black wire at the solenoid) goes 12V + every time you turn the switch, particularly when you do not turn it hard. If this is an automatic you should also listen for the park/neutral relay to be clicking each time you try to engage the starter.

I believe that is the fan control module. There are a couple of things you can do to check out the starter. If you don't have a heavy gauge remote switch you can sacrifice a screwdriver to jumper across the two large terminals on the starter solenoid (be sure it is in neutral if this is a manual) and the starter motor should engage. If the motor seems okay you can use a test light to see if the trigger wire (small red/black wire at the solenoid) goes 12V + every time you turn the switch, particularly when you do not turn it hard. If this is an automatic you should also listen for the park/neutral relay to be clicking each time you try to engage the starter.
Your advice has been good again. I was able to start it with a remote switch and there is no power to the solenoid. How can I determine if it is the park neutral safety relay? What else can you recommend. You helped me fix my cruise control now I need your help to use it beamdream

Hi, this is great -- I have the exact same problem - found this site and thread by searching on Google. Mine is a '93 VR6 (well, Im slightly concerned that its a VR5 right now but thats another topic!).

The starter works fine when I jump +12V from the battery to the starter solenoid, but not when trying to start from the ignition key. The key-switch IS working, because I hear relays clicking, lights and radio switches off, seatbelts move to their open position (should they do that?) etc. So my guess its I´ve got a faulty relay somewhere, or perhaps a lose cable or corroded connection. I don´t have a wiring diagram or even the original owner manual so I´m a bit stuck as to where to look.

The problem started about two weeks ago, when occasionally the starter would fail to work, and it has deterioated since then to hardly ever working. I took it to a local (not VW) shop three days ago who assured me from my description of the behavior that it needed a new starter motor. Today, expecting to pick the car up fixed, they told me that it was some other electrical problem and they couldnt fix it (their electrician is away) Great! :( Well, at least I´m pleased I don´t have to pay for a new starter.

Ok, so now I´ve left a piece of wire attached with a crocodile clip to the starter solonoid which I just need to touch on the battery terminal to start the car. Inconvenient, but better than having to look for hills to park on which is what I´ve been doing for the past few days!

Only had this car for a few weeks... I´m beginning to think I picked up a dud :(
will post other problems here in a moment.

Any ideas please? A corroded contact somewhere? (where?) or a failing relay? (which?) All ideas appreciated!

P.S. I originally trained as an electronics technician so I can understand relays and stuff, but I´m not too familiar with this car having owned it only a few weeks, so please explain WHERE to look for anything you suggest I go and check.

P.P.S. As a complete aside, this car originally came from somewhere in the US, has been in Spain for quite a few years, then England (where I bought it) and is now back in Spain again with me! I swapped my beloved ´92 Nissan 100NX 2-litre for this... bad move I think :(

Thanks

Andy

I would need to know if it is automatic or manual, and also if it has the anti-theft system to help further.

I would need to know if it is automatic or manual, and also if it has the anti-theft system to help further.

Sorry that was dumb of me not to say -- it's a manual. As for anti-theft, it has SOME kind of alarm system - I don´t know if its the factory system or an after-market add-on. If I manually unlock and open the boot... um... tailgate... without first unlocking the doors then the horn sounds (not a siren). Also, there is a red LED on the drivers door, right by the lock button, which lights up when you lock the door.

One other piece of information that may be relevant.. I remember noticing (back when it usually worked) that there was a slight delay between turning the key and the starter actually turning. It was about half a second. So a sticking relay seems to me a logical explanation, the question is which.

Andy

That would be the anti-theft system, does it seem to function properly? If not you can try bypassing the starter lock-out function. I think the module is located under the left dash, it has two connectors - one 6 pin & the other 10 pin. You can jumper the wires from pin 5 (red/green) & pin 6 (red/black) of the 6 pin connector to disable this function. There is no relat in the system (other than the starter solenoid itself). Often the problem is a voltage drop due to resistance in the wires. You can install another relay into the circuit near the starter to get better voltage to the starter solenoid. Run power to the relay directly from the battery w/heavy gauge wire, then from the relay to the starter solenoid. Then run the existing wire from ignition switch to the trigger side of the relay. I hope I made this clear enough, otherwise your mechanic should understand.