Hard to start....suspecting solenoid?

[Rich_91]

Hi.

I am having a hard time starting my 91 Jetta 1.6td. The situation is this:

When the motor is cold, and you try to turn it over, it cranks for about 2 seconds, then it stops. What I mean is that even though I hold the key in the start position, it only is actually turning the motor for about 2 seconds, after that you can hear what sounds like the starter motor turning, but the solenoid is not engaged. It gets to the point where sometimes it will only turn the actual engine over for 1 revolution. then I have to turn the key to off and back to start, 1 revolution, etc. This makes it incredibly hard to start.

Things I have done to try and fix the problem.

1. New Grounding Cable
2. New Battery terminal ends.
3. Had battery "Load Tested", and its ok

Could the starter solenoid be toast, since it almost seems like it wont stay "pulled in"?

Is the solenoid replaceable on these?

Thanks for the help.

[zukgod1]

I haven't seen a replacement solenoid but that doesn't mean that there isn't any available.
Try removing the starter and cleaning it up?

[burn_your_money]

Yes it is replacable. Your 91 should already have the gear reduction starter, just keep that in mind. Not sure if it makes a difference

[jtanguay]

its the starter.. mine did this as well.. night and day comparison with a rebuilt starter.

you could probably fix it yourself if your handy enough though.  just bring the starter to one of those rebuild shops and then get the rebuild pieces and do it yourself.  you can even test the solenoid to make sure its working right by jumping it with 12v current.

thinking more about this... the starter will only spin when the solenoid is fully engaged... as the solenoid has two functions.  1 - to engage the teeth to the flywheel 2 - to bridge the connection to spin the starter. so i doubt it will be the solenoid if you hear the starter doing something...

[Rich_91]

its the starter.. mine did this as well.. night and day comparison with a rebuilt starter.

Turns out that you were right. I was at a local rebuilding shop and bought a solenoid for $20. Took the starter off and inside to work on it. After a bugger of a time getting the rotted phillips screws out of the old one, I got the new one in and back onto the car.

Unfortionatly, it still does EXACTLY the same thing. It cranks one or 2 turns, then it freewheels.

I talked to a local VW guru, who told me its more likely to be the starter "drive".

Should I attempt to undertake this myself? A rebuilt complete unit from NAPA is like $250, which is a heap of money (to me, anways). Plus, I already have the new solenoid on there.

I tried the used starter method, but couldnt find any diesel starters at the wreckers.

[rallydiesel]

That's bizarre. Did you try the starter out of the car? Have you checked the ring gear for missing teeth?

[jtanguay]

its the starter.. mine did this as well.. night and day comparison with a rebuilt starter.

Turns out that you were right. I was at a local rebuilding shop and bought a solenoid for $20. Took the starter off and inside to work on it. After a bugger of a time getting the rotted phillips screws out of the old one, I got the new one in and back onto the car.

Unfortionatly, it still does EXACTLY the same thing. It cranks one or 2 turns, then it freewheels.

I talked to a local VW guru, who told me its more likely to be the starter "drive".

Should I attempt to undertake this myself? A rebuilt complete unit from NAPA is like $250, which is a heap of money (to me, anways). Plus, I already have the new solenoid on there.

I tried the used starter method, but couldnt find any diesel starters at the wreckers.

i think you might just need new brushes... go to a rebuild shop and get all the little pieces.  if you can replace the solenoid, i'm sure you won't have too much problems with the brushes.  there are tons of writeups all over the net (with pics) showing how to do it as well.

[CODE4LS1]

I believe the part you're looking for is the bindix drive.  It's basically a one-way clutch that has gone bad.  Good luck!

[fatmobile]

Yep, just had the same thing happen on one of mine. ziiiinnnnggg
 The rebuilder says the clutch was probably bad.

[Smokey Eddy]

I cleaned a significant amount of crap out of my starter. The brushes do wear though which worried me when i looked at mine. they looked like they were getting thin.

[rabbitman]

I talked to a local VW guru, who told me its more likely to be the starter "drive".

I believe the part you're looking for is the bindix drive. It's basically a one-way clutch that has gone bad. Good luck!

Yep, just had the same thing happen on one of mine. ziiiinnnnggg
The rebuilder says the clutch was probably bad.

Correct, the starters one-way clutch is your problem. You can get 'em on ebay or from starter rebuild shops. I bought one for $30, way cheaper than a rebuilt starter. This requires complete disassembly but it's not very hard to do.
One little tip, when you put the new one on do not lube the splines on the shaft! When the grease thickens in the cold, the drive gear won't be able to slide out fast enough and it'll hit the flywheel spinning and break the teeth off.

[jtanguay]

One little tip, when you put the new one on do not lube the splines on the shaft! When the grease thickens in the cold, the drive gear won't be able to slide out fast enough and it'll hit the flywheel spinning and break the teeth off.

i thought the motor will not engage if the solenoid isn't fully extended, to eliminate this from happening?

[rabbitman]

i thought the motor will not engage if the solenoid isn't fully extended, to eliminate this from happening?

Yup, but the arm that slams the gear out actually pushes on a spring that pushes the drivegear so the solenoid thinks the gear's out all the way out but the spring is compressed and the gear is in front of it slowly sliding out. It's maddening hearing my new flywheel getting chewed up :x

[Rich_91]

So I begged and pleaded with one of the local rebuilders, and he gave me a great deal on a reman one....and WHAT A DIFFERENCE!!

Not only is the drive not slipping, the thing turns over WAY faster than the old one.

My jetta started with no problems at -25 C yesterday morning, without being plugged in.

Im not giving him back the core, so I am going to take my old one apart and rebuild it myself, for a spare.

So if your diesel has trouble starting, make sure that starter turns that motor FAST!

I use Shell Rotella T  15w40, and no problems!

Thanks for the help ppl!