Starter Problems?

Derek Pulvino dbpulvino at
Mon Dec 12 13:05:42 EST 2005

Well, yesterday got the voltmeter out and I do have 12v at both the main 
power in to the solenoid and the trigger wire from the key (when it's 
turned).  I did also find that the insulation on the trigger wire is 
absolutely destroyed on the last 4-inches or so of the wire.  I haven't 
checked resistance on those components or on that jumper wire.

So, after finding the above pulled the starter out and had it bench tested; 
it turns over fine, but I wonder if a load condition would effect the 
actuall if it had been bench tested under load if the motor 
still would have turned.

The other question I had is if volts is really the right measurement.  
Wouldn't corroded wires restrict the current flow?  Is that were looking for 
voltage drop under load vs unloaded comes in?

Derek P

>At 04:47 PM 12/11/2005, Derek Pulvino wrote:
>>Now that I have some light, I'll be checking those things today.  Reading 
>>at Blau, I also saw that there's a large gauge jumper wire that runs from 
>>the solenoid to the starter motor that can also be suspect.
>>I'll post back with my findings.
>>Derek P
>>>I'd start by checking out the wiring at the starter itself.  There's the
>>>big wire that carries power to operate the starter and there's the little
>>>wire that comes from the switch to tell the starter to start operating.
>>>The former can have corroded contacts and the latter can deteriorate
>>>internally because Audi seems to use starter wires whose insulation isn't
>>>very good considering the environment it works in.
>Large gauge wire from Solenoid to starter is what carries the power to the 
>motor brushes.
>For some unknown reason Bosch saw fit to NOT insulate the wire, even though 
>it carries ALOT of current.
>It is also the major weak spot on the starter.
>Use an ohmeter and check for any resistance between the post on the 
>solenoid where it attaches ( 10 or 13MM nut) and what appears to be the 
>starter body ( is actually insulated area for the motor brushes) .
>If you are lucky it might just be some corrosion on the post on the starter 
>If not you will either have to replace the lead (with one from another 
>starter), have the starter rebuilt locally, or a replacement starter.
>1991 200 20v Q Avant Titan Grey
>1991 200 20v Q Avant Indigo Mica
>1991 90 20v Q Red
>1990 CQ silver (awaiting S2 engine transplant)
>1990 CQ red ( to part or not)
>Chelmsford Ma, USA

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