car will not start after driving for 30 minutes

[vwroadkill]

Hey. I drove my car this afternoon running errands. stop and go traffic. arrived home.. car will not start. sluggish turning over.. tried jumping it off.. thought maybe battery dead.. its new... but no glow plug light, but the car was warm.. I just shut it off. and it would not start back up.. fuel lines are full no air.
confused  did I miss something..
Dan

[TylerDurden]

If it won't start with a jumper cable, starter is suspect.

If it starts with a jump, starter is ok - keep it running for test:
Check the battery & alternator voltage, If >13V, battery & grounding are suspect
If low (<13V), check for voltage at the Glow Plug fuse or GP#1 (engine running)
If GP fuse has voltage, relay is stuck on, sucking the juice.
If no voltage at  GP fuse, check alternator, big cables/connections to battery (>13.5V), if low turn OFF engine.

Check for adequate tension on alternator belt, pulley should not slip by pushing on alternator fan.
If alternator belt tension ok, turn key to ON, do not start, check blue wire on alt (D+) for >1.5V
If no voltage at D+ with key on, wire is suspect. Start engine and momentarily jump 12V to D+ terminal (1 sec) and check battery voltage: >13.5 volts means OK alternator, <13V means alternator should be bench tested.

[8v-of-fury]

Unlikely, but did you over heat it?

EDIT: TD ninja'd me... lol

[vwroadkill]

Tyler, I will have starter checked out.starter was rebuild in september .. but it would not start.. with jumper cables hooked up to turned over fine.
I was going to check the GP fuse.. not relay? I have a fast relay on fuse block.
I made certain that I never let it. turn over for more than 15 seconds..
I took all grounds off, cleaned them with a wire brush and the mating surface...covered them with a dielectic grease.
after reading what you posted and doing what you suggested is to bench check the alternator . and swapping the relay with another one
Dan

[TylerDurden]

Tyler, I will have starter checked out.starter was rebuild in september .. but it would not start.. with jumper cables hooked up to turned over fine.
- If jumpers start the engine, the starter is probably ok.

I was going to check the GP fuse.. not relay? I have a fast relay on fuse block.
-If the GPs stay on >15sec after the engine is running, relay is faulty. Probe at the fuse or GP#1.

I made certain that I never let it turn over for more than 15 seconds..
- up to :30 is ok by VW, shorter is better tho.

I took all grounds off, cleaned them with a wire brush and the mating surface...covered them with a dielectic grease.
- Supply cable connections can be resistive too.

after reading what you posted and doing what you suggested is to bench check the alternator . and swapping the relay with another one
- If the alternator fails to supply >13.5V with no loads, belt and dash LED wire is ok... alternator needs bench testing.

(Any basic DMM will be fine for the above tests, even cheapies from HF.)

Additional notes:
If the starter was serviced, but the bushing in the bellhousing was not changed, the starter may struggle. (First I'd check battery/charging/loads.)

Starters on some auto trannys got too hot by the exhaust, due to missing heat-shield and/or undersized starter. Manual tranny starters are in front of tranny and don't overheat unless overcranked.

[vwroadkill]

based on what you've wrote and asked me to check..thank you for your time.. I am going to have the alternator rebuilt.I did not get 13.5v I will also change out the relay just to be sure...
I did replace the bushing when i re-installed the starter.
I did put new grounds from battery to chassis, battery to starter, when I brought car home..
 I have been replacing stuff on this car since I bought it.. shortly I feel I will have a new car. drives me crazy
but what fun would a project be without grey hair and new curse words..
Thanks Tyler..
I will reply when I get new or rebuilt alternator installed
Dan

[fatmobile]

If it's cranking slow and won't start:
That's a great oportunity to crank for a long while then jump out and feel all the big connections.
 If they are hot/warm you have a bad connection.

[8v-of-fury]

or a dieing starter pulling way to much load.

[vwroadkill]

Today,I pulled the alternator.. it was dead.. brushes and the commutator[sp] where smoked.. should be ready tomorrow..had to work late yesturday.and it rained all day. I didnt feel like being outside anymore than I had to. did find a few good deals at the box stores.. 57.00 for a motorala look a like, but I decided to take a known [dead] alternator to the electric shop and let them rebuild what I had.... 8V, I did suspect the starter at first. the shop that rebuilt the starter is doing my alternator.. they asked that I bring it by with everything running.. to give it a once over..
the owner of the shop stands behind all his work and labor... hard to find good shops like this anymore... so buying local does pay off, even if you pay a little more.
will let you guys know what happens after I install the alternator.
oh and Tyler, can I drop ship my truck to you... you where spot on. thank you.

[8v-of-fury]

When you install the alt, be sure to have them really check it over when you take it there.. If something is causing extreme load, it could kill the alternator again in short order.

[vwroadkill]

thought about just starting it with it installed and not plugged in..driving it to the shop and then plugging it in and having them do there thing ... might be worth my time and money to do that.
Dan

[8v-of-fury]

If the battery is fully charged, and you do not have the lights or fan or anything on you will be able to run for hours.

[vwroadkill]

thought about that this afternoon.. after I pulled one aircraft generator, swapping it out and having to deal with the paperwork, I barely felt like screwing.around with my truck today. I was just going to load it on the trailer and take it to them, let them have the head ache.but as my son put it... why let someone take the fun out. so I will just listen to my son, write that down, and do this.
should be fun tomorrow...
and if anybody wants to help. Iam going to pull an oil pan off a passat and change the oil pan... they curb hopped.

[vwroadkill]

well I did it.. it runs...although I will have to learn more about alt. and starters... alternator was dead..fixed... killed battery... jumping off and overheating starter, killed starter..got all fixed.. rebuilt starter again.. I did it.. so I split the cost with the shop..I paid for labor. they bought parts.
So Tyler Durden and 8V, I owe you thanks...
being as we are geographically separated, I can only say THANKS.. if closer..it would be beer.

Dan

[TylerDurden]

Glad to hear it's sorted. I'll hit ya for a cup o joe if I'm ever down there.