Date: Sat, 5 Jul 2014 00:43:52 -0600
Reply-To: OlRivrRat <OlRivrRat@COMCAST.NET>
Sender: Vanagon Mailing List <vanagon@gerry.vanagon.com>
From: OlRivrRat <OlRivrRat@COMCAST.NET>
Subject: Re: $100 Reward to Solve Starter Problem
In-Reply-To: <BLU174-W244FB3065CE352DE932E6D2010@phx.gbl>
Content-Type: text/plain; charset=us-ascii
Richard
Just to clarify 1 point ~ If you turn the Ign'Switch to "On" does the Solenoid Activate
or do you have to Switch to "Start" to get it to Activate & then when returning to "On" it
will not Disengage ~
ORR ~ DeanB
On 2 Jul , 2014, at 7:32 PM, Richard Golen wrote:
> Dear Vanagon List Members,
>
>
>
> I am offering a $100 Reward for the solution to my starter problem. Please
> read all of this carefully before suggesting your solution. The reward will be
> sent via PayPal or via check.
>
> The
> "patient" is a 1987 Vanagon Westfalia with a manual transmission. The
> "problem" starter solenoid will not disengage when key released from
> "start" position. Sometimes, I can quickly switch off and back off
> and the starter will briefly disengage, but will re-engage.
>
> Here's what I have observed. On a trip to Lime Rock Park two
> weeks ago, while on the interstate, smoke and electrical wire burning smell
> started coming out of the area under the rear seat in the area of the ECU. I
> quickly shut off the engine, coasted to the breakdown lane. Popped the rear
> seat and the cover to the ECU to see if the problem was, in fact, the ECU. The
> only thing I noticed was the cooling fins on the ECU seemed to be hot. I let it
> cool down, restarted the engine, and drove off. No problems the rest of the
> trip to Lime Rock.
>
> Two days later when we were leaving LRP, I started the
> engine and the revs went from 800 to 1500 to 2000 to 2500. Blipped the
> throttle, no change. Shut off the engine, and checked the engine. Throttle and
> cable were not binding. I disconnected the idle stabilizer and the revs dropped
> to 800. While checking things out, I noticed that one of the wires from the
> power steering sensor had come loose and grounded out. Taped the connector so
> it wouldn't ground out again on the way home.
>
> The next day I installed a new Bosch rebuilt starter. I had
> planned on replacing the starter as it was getting old. The new starter worked
> perfectly. However, the next morning when I started the van the starter would
> not disengage. Shut off the ignition, turn it back to on, engine was running
> but the starter did not disengage. I did
> put the old starter back in, and it too was doing the same thing. Put new
> starter back in.
>
>
> Here's what I've done so far:
>
> 1. replaced the ignition switch. Still same problem.
>
>
> 2. made a jumper for the ignition switch plug with 4 male
> terminals. One terminal to the + from the battery, one to the fuel pump side of
> the switch, one to the ignition (warning lights came on with this), then I
> jumped the wire to the starter solenoid. Engine started, disconnected wire.
> Engine ran, but starter did not disengage.
>
> Tried it again. Starter did not disengage when I
> disconnected the starter wire. This time, I disconnected the fuel pump wire and
> the starter disengaged. With my multimeter, I checked the voltage at the
> solenoid. No voltage with the switch off. With the switch on, but not to start,
> power to the solenoid. Disconnected the fuel pump wire at the ignition plug,
> and the power to the solenoid lead went off...no voltage.
>
>
> 3. Disconnected the auxiliary battery and auxiliary battery
> relay. No change.
>
>
> 4. Checked the wiring harness in the engine compartment that
> contains the leads to the power steering sensor and the plug to the idle
> stabilizer. The power lead wire to the sensor had grounded out, heated up and
> melted its insulation as well as some of the insulation to the power lead to
> the stabilizer.
>
> I figured voila! Found the problem. Repaired the wire to the
> stabilizer, put in a new section of wire for the power steering switch. Started
> the engine, and starter would not disengage.
>
>
>
> 5. Swapped out the idle sensor relay. No change.
>
>
> 6. I removed the ECU and popped the cover. I couldn't see
> anything that looked burned.
>
>
>
> I've poured over wiring diagrams in the Bentley as well as
> some that are online and am at a loss. The only other potential part that could
> be remotely related to this issue is the ECU. I have a spare one coming in the
> next few days, but don't want to put it in until I'm sure I'm not going to
> damage it.
>
>
> The only option I see is to run a new wire from the ignition
> switch to the solenoid, perhaps using a relay.
>
>
>
> So, here's the challenge. What could be the problem? I will
> pay $100 to the person who is able to diagnose the problem and I can get the
> starter to work properly. I will be more than happy to provide more info or
> answer any questions.
>
>
>
> Thanks in advance.
>
>
>
> Ric
>
> 87 Westfalia
>
>
>
>
>
>
>
>
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