PLEASE HELP, My Parents need your skills/knowledge

[gribur]

Here is a copy of a letter we put together and sent to VW Canada.  It is turning into a bad situation as they can't rely on their car and the dealer and ourselves cannot find the issue.  My father is what I would call well versed  when it comes to DIY auto repair and has more then enough skills (was a control tech at a nuclear power plant), yet it still eludes us.  Please give us a hand, and maybe let us know if you are having or have had the same issues.
   I know somebody here will be able to start to figure it out just from the letter, I am positive there is enough knowledge and more then enough years experience here to get this solved.  Here is the letter, cheers guys.

"We own a 2000 Jetta TDI. I am a firm believer in VW cars and have owned many over the years and never have I had the problems like I do with this Jetta. From going on the different forums re: vw Jetta I am not the only one with the problem. It would seem there are hundreds of people with the same difficulties with the Jetta, yet nobody can pinpoint the issue.

This car will not start with out being jumped it is not dependable our VW dealer has no idea what is wrong. We have a new battery, everything that could be replaced has been, including relay number 9?(glow plug relay), starter and the temperature sensor . This car is breaking us financially.

It is almost as if the car has some sort of parasitic drain. It will also not start if driven enough to warm up, let sit for approx. an hour. It seems to be a temperature sensitive issue also. Please contact me and help us with this problem I am very sure everyone on the forums for VW cars would be greatly appreciative of this problem being solved.

Our car SHOULD be good for another 10 plus years. This car has had this problem for years. We can't figure it out or take it any more. VW's should be dependable cars. We live in the country and are being held hostage by Our Jetta."

[745 turbogreasel]

new starter?

[Syncroincity]

Good luck, they'll probably deny the car was ever manufactured, then sue your parents for defamation. '99-'03 VWs are poison. Sell it, move on. Not worth the effort.

As far as a fix, have ALL the starter-related wires been looked at? Engine & Trans ground straps in particular. I'd put money on a grounding problem.

Hope you find something, it's hard to diagnose this without a complete list of what's been replaced...

[Patrick]

SOunds like my '92 with AAZ (which you've seen). Battery will take a 450 amp draw for 45 seconds and still show good, cleaned all the grounds and positives, charges to 14 volts, and every once in a while I walk outside to go to work and the battery is dead. Seriously considering a main disconnect switch on the negative cable like we use on heavy equipment, it will at least eliminate any possible draws... You can buy a battery terminal that is a big switch, might be worth a try. You'll lose all the presets on the radio and clock every time you shut it off though........

[maxfax]

As far as a fix, have ALL the starter-related wires been looked at? Engine & Trans ground straps in particular. I'd put money on a grounding problem.

X2..  I had an '02 in the shop with a similar problem.. We added a few extra ground straps..  So far so good on that issue..   Everything else about the car is job security for me...

[Settings]

X2..  I had an '02 in the shop with a similar problem.. We added a few extra ground straps..  So far so good on that issue..   Everything else about the car is job security for me...

Curious...where did you add the extra ground straps?

[the caveman]

MK4's were notorious for having poor ground connections from the factory. All the ground connections should be removed, cleaned and reattached with dielectric grease. These include the one large and up to 7 that are located under the battery tray. Also the large connection that goes from the battery to the engine,which attaches to the studded bolt that goes through the bellhousing, and including the surfaces of that bolt. Also the ECU grounds near the ECU under the plenum [where the wiper assembly is] cover.
Try taking a booster cable and attach it between the battery and block.
Also try using a wire to engage the starter directly from the battery to the starter rather than all the way from the fuse block on the battery, into the car, through the fuse box, though the ignition switch, though the fuse box again and back to the starter[ see why i mention this?]

[maxfax]

Curious...where did you add the extra ground straps?

Lemme try to remember, I diaged it, he took care of the problem.. He took one of those battery ends that have a stud and nut on it.. IIRC he Connected all the originals, plus one right to the starter bolt, one to the body, one to the ecu, one to the alternator bolt....   Overkill possibly, but it hasn't given trouble since.

[v_dub91]

It also maybe a wiring issue like a fuseable link or lile a bad ground or something like that. Just a thought