[Vwdiesel] Still having starting issues with the 82 vanagon diesel

Erik Lane eriklane at gmail.com
Wed Sep 16 08:19:45 PDT 2009

To be absolutely sure that you have found your problem, check the
voltage drop from the cables with a meter while trying to start. Put
one lead from the meter at each end of one of the cables and measure
voltage while cranking. Then repeat for the other cable. Anything more
than .1 or .2V is suspect, I think. Definitely if you're seeing
anything like .5V or 1V drop in each cable you've got problems. If
you're thinking of having a cable made up I would make sure to get
something really heavy duty. I'm not sure an Autozone place would have
anything good enough. You want welding cable sizes. Really fat. If the
cable isn't frayed inside then I don't see how it would be bad in
there - likely just the ends have too much corrosion. If you get the
ends off of the cable and clean up the copper really well and have
some place put new ends on for you that will probably work. It wasn't
exactly cheap, but we picked up our own end crimper to be able to do
exactly that. We've reused quite a few cables very successfully by
replacing the ends.


On Wed, Sep 16, 2009 at 7:54 AM, Bryan Belman <dieselwesty at yahoo.com> wrote:
> I am getting closer to finding this gremlin, I think battery cables are next.
> Here is what I have done,
> 1. load tested battery with a cheap load tester, but it says it is good, this is group 41 battery from my old Audi 200, 850CC AMP, it is good.
> 2. Cleaned all battery terminal ends, saw some green stuff on the end that connects to the starter, hit it with wire brush and put some sodder in there, this is the issue still, I think.
> 3. starting the van now with my original ignition switch almost 100% of the time, motor turns over but not fast enough to start I guess, seems to turn fine, but does not start.
> 4. using a new ignition switch and a screw driver, it starts right up when cold, every time.
> 5. Then when the motor is hot or warm, I get the same results using the original ignition switch still in the column.  plug into the new ignition switch, I get a clunk, I can hear the starter solenoid go clunk, but no start.  Try again, clunk.
> Now for the key........
> My temp sender to sense when the coolant temp is hot does not work or is the wrong one,  my glow plug relay does not get the signal and always has been cycling the 7 seconds for the glows.  Yes, I need to fix this.
> So, when the motor is hot and I let the glow plug cycle complete, say 8 seconds, then the motor will turn over, no clunk of the starter solenoid.
> OK, this is certainly electrical.  Should I get new battery cables made up?
> Is there a certain size I should get for the diesel or do regular battery cables from any Autozone place work?
> Thanks, this is driving me nuts............... it has been an on-going issue for a long time but I have never swapped battery cables.........ahhh, that must be it.
>  Bryan Belman, Pt. Pleasant, NJ
> 04 Jetta Wagon TDI PD, 100hp, 5sp -- running :)
> 92 Jetta 1.6 Eco-Turbo Diesel -- running :)
> 82 Diesel Westy 1.9NA -- running :}
> 70 Type 1 stock Beetle -- Not running :(
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