Sharan AHU starting mystery

[the_old_diver]

Over the past month my 1.9 TDI has got increasingly reluctant to turn over - hot or cold. I have tried 3 different batteries and also used a jump lead from the battery negative to the engine block hoping to bypass a bad earth, but it makes no difference.

The main clue is that although the starter clicks and tries to turn, the dashboard lights do not dim. The starter itself is fairly new - 3 or 4 years old.

Last week AA man (in supermarket car park) checked the 2 positive connections on the starter assembly and after cleaning up the connections the engine started again but I noticed a bit of arcing and sparking from the connection when he started the car. Obviously I can't check that myself.

As mentioned in a nearby thread, I do have a "known to be working" 0986 016 310 1.7 kW starter off my old Passsat AAZ engine and I'm wondering if it is compatible with the 0986 016 980 1.8 kW starter on the Sharan.

Advice on compatability and possible fault would be appreciated.

Thanks, OD

[scotty33]

You could try the swapping just the solenoid first?

[the_old_diver]

Hi Scotty33,

I have brought the Passat starter into the house and after a period of warming and penetrating fluid I have removed the 3 torx T25 screws that hold the solenoid to the starter assembly. (Tip, remove the nut holding the electrical braid to the solenoid before removing the three screws).

I am now wondering why you suggest swapping over the solenoid first, as I have to remove the starter unit from the car to separate the solenoid from the starter body, so why not just swap the whole assembly?

Thanks for your input. OD

[phil miller]

if things dont go well ive got a sharan starter motor here works perfect, if you cover postage and a few beer tokens its yours if you need it mate

[the_old_diver]

if things dont go well ive got a sharan starter motor here works perfect

Thanks Phil - that's good to know. At the moment my offending TDI is buried in the snow on my driveway, but I'll get the starter off it asap and try scotty33's suggestion first; if that doesn't sort it I'll be PMing you.

Thanks Mate. OD

[scotty33]

Sorry, OD, thought the sol would come off without removing the starter, it sounds to me like it could be the culprit, if there is a difference in the starters you have, then this may be a way out of the problem?

[the_old_diver]

Hi Scotty33,
Your suggestion is good and I will find out about compatibility once I have got the starter off the Sharan, which is presently on the lawn under 6" of snow.

I think I will find something else to distract me this afternoon :-)

BTW I bought another Sharan last week, 6 months newer, R reg petrol 2-litre GL for little more than the cost of the new tyres & battery which are on it. What a difference! 22 mpg vs 49 mpg on the P reg TDI, doesn't go up hills so well but the heater works brilliantly and the temp gauge goes straight to the "normal" position with a mile or two and stays there, unlike the TDI which never goes past "half past nine" and drops back when stuck in traffic.

It's strange that the 2-litre petrol engine should be so greedy compared to its diesel brother when moving the same vehicle. Still I should be thankful that I have a car which starts immediately and is nice and warm, and even 22 mpg is much cheaper than a taxi ride.

[the_old_diver]

Sorted!
OK, I swapped the solenoid from a 96 Passat 1.9 TD AAZ part# 0 331 303 147 onto my Sharan 1997 TDI CL AHU and have now got a running car again.

Had to remove the intercooler duct section that runs near the starter motor, and fiddle around with the cable holder which is bolted on to one of the starter mounting bolts, but no big deal - just spanners and confidence and pentrating fluid.

To repeat the symptoms, car got increasingly reluctant to turn over, eventually refusing altogether. Althought there was a click from the system when I turned the "ignition" key to the start position, the starter didn't turn and the dashboard lights did not dim as they would with a flat battery.

Hope this helps someone.OD Thanks Scotty 33

Now I have just realised that I don't have any essential journey to make today, but I did cut a nice piece of carboard which is now hanging just behind the front grille on a couple of pieces of mains ringmain cable to prevent excessive cooling.

Does anyone know if they still make those rather posh radiator muffs like my Dad had on his Wolsely 6/90 - beautiful leather thing with chrome press studs?

[scotty33]

Sorted!
OK, I swapped the solenoid from a 96 Passat 1.9 TD AAZ part# 0 331 303 147 onto my Sharan 1997 TDI CL AHU and have now got a running car again.

Had to remove the intercooler duct section that runs near the starter motor, and fiddle around with the cable holder which is bolted on to one of the starter mounting bolts, but no big deal - just spanners and confidence and pentrating fluid.

To repeat the symptoms, car got increasingly reluctant to turn over, eventually refusing altogether. Althought there was a click from the system when I turned the "ignition" key to the start position, the starter didn't turn and the dashboard lights did not dim as they would with a flat battery.

Hope this helps someone.OD Thanks Scotty 33

Now I have just realised that I don't have any essential journey to make today, but I did cut a nice piece of carboard which is now hanging just behind the front grille on a couple of pieces of mains ringmain cable to prevent excessive cooling.

Does anyone know if they still make those rather posh radiator muffs like my Dad had on his Wolsely 6/90 - beautiful leather thing with chrome press studs?

You brave man, spannering in this...
Then again 20mpg might spur me into action too