Golf Tdi PD Intermittenet starting problem

[minitrio]

My sons Golf 1.9Tdi PD (2001 Y reg with 80k on the clock) has an intermittent starting problem which can occur regardless of engine hot or cold and cold or hot weather. The battery and alternator have been tested and are working correctly and a new starter motor has been fitted which is definitely better at turning the engine over than the old starter but has not cured the intermittent starting.

When the problem occurs all the warning lights come on including the glow plug light with the ignition on. When the glow plug goes out the key is turned into the starter position and it sounds like the battery has packed up and all the warning lights virtually go out. If the ignition is turned off then its turned on until the glow plug light goes off then turning off two or three times then the next time engaging the starter and this has worked so far.

Any ideas really welcome...

[phil miller]

it sounds like you have an ignition switch preoblem, when the car fails to crank over have a test light and see if the solonid wire on the starter is going live when the key is turned, one thing though, but id have thought when the starter was replaced it would have been noticed is, ive had it once before where the solonid wire has broken inside the plug, sometimes it made contact sometimes it didnt, worth a look, the other thing it could be is an earth fault have a good look at all the earth wires

hope this helps mate

[minitrio]

Thanks for the quick response. Do you know how difficult it is to replace the ignition switch and any hints / tips would be appreciated.

[herby0001]

Have you checked the wiring under the battery? Could be a degraded/corroded wire or a poor connection.

[minitrio]

A quick update. We have found that if when the ignition is turned on we wait until all warning lights go out (not just the one for the glow plugs), (the last one being the air bag) it starts on the button. One thing that happened last night I got a call from my son who had driven the Golf about 60 miles and turned off the engine. When he came to start it a short time after the problem reoccurred, but having discussed it further he actually had switched on the ignition (without the engine running) and left an indicator on for several minutes before trying to start again. Does this point more towards an ignition problem again? I have told him not to leave the ignition on like that again and use a parking light instead or hazards.