1.6 Mk3 - Random cut outs - electrical?

**listerthrawn** · 11-02-2009,12:00 AM

Hi,

Sorry for my first post to be a cry for help, but so it is...

I've a 98 1.6 Golf Mk3 (new engine type 100bhp model) which normally works just fine. Sometimes however it just dies whilst driving. This can happen when travelling slowly, or whilst doing 70mph on the motorway, there's no pattern at all. My mechanic has had this car in time and time again and can't reproduce the fault at all. Due to a separate failure I've had a new ignition coil and distributor.

Here's the strange thing though. When it dies, it will not restart immediately, the starter turns, but there's no attempt at the engine firing up, until I hear a click noise (like a relay click) and then the engine starts just like nothing has happened.

Second strange thing, is when this click happens, the rpm gauge jumps like it was flicked. It jumps to nearly 1000rpm. The engine is not moving when this happens and neither is the car. The ignition is on (i don't touch the key now until I see this jump). I know if I wait for this, the car will restart every time. The time between the car cutting out and being able to restart it is about 15-25 seconds.

If anyone is reading this because their car cuts out randomly, I urge you to look out for the rpm display flicking up. If it does, please post!! You don't have to do anything. When it cuts out, just sit and watch the rpm (if it's safe obviously!!)

The fault is also so intermittent. At one point it was happening daily. It happened today for the first time in probably 10 months. It's the most annoying car problem I've ever had.

Any ideas at all are most welcome.

Thanks

Chris

**fjsmits** · 12-02-2009,05:46 AM

I had a similar problem with my 1997 GL golf. It appears to be the ignition switch. When the problem occurs just try and start the car but at the same time try and move the key inside the ignition switch. It would be as if the ignition circuit sometimes does not make the connection and sometimes does. I could be driving down the road at 100kmh and it would happen or I could be just going through the gears.

In the end I just replaced the ignition switch(electrical) and it has been ok ever since.

Hope that helps.

**listerthrawn** · 14-02-2009,11:23 AM

I've already tried this but it doesn't seem to make any difference.

Not sure why the clicking noise and why the RPM would jump because of this either.

Thanks for the post! I'll give it another go.

**fjsmits** · 14-02-2009,11:39 AM

Where does the clicking noise come from?

It could be the engine to body/battery earth.

That may explain the clicking and the rpm jump...earth/bad earth.

Check the earth cable that is bolted to the gearbox from the battery.

**Cragus** · 16-02-2009,06:09 PM

I've had this problem and it turned out to be the Ignition Coil which is situated on the back of the engine bay just behind and right of the air intake. The clicking could be an arc between the coil and the bays metal body caused by a cracked coil casing. Ignition coils are not expensive and easily fitted. Open the bonnet at dusk then start the engine. Listen for the clicking and look for the spark. I hope this helps.

**alangolfgti** · 18-02-2009,09:07 PM

Hi, i have a mk3 gti AAG engine and i have the very same issue. haven't seen the rev counter do that but i'll look out for it. had it in the garage - no joy and also a Auto electric specialist. they hooked it up and could not find the problem.....

then it cut out on them - they kept it a week - they replaced the coil but it still did it.

the computer they connected it up to said there was no problem. but when it cuts out there is no spark while cranking the engine. they also disconnected the immobilizer. still did it. they gave it back to me.

i have changed relay 30, nope. cleaned the throttle body, nope. just did it to me today on the M25. it will start again when it wants, but always if i leave it for a few hours.

the clicking sound i get is from the fuel pump relay, if you remove the fuse cover then you can hear and feel it. dont know if its cause or effect though.

suspect it might be the ignition switch or the fuel pump relay

any advise would be very welcome

Please help as the pro's have given up on me so its down to us now.
cheers

**Mardus** · 18-02-2009,09:14 PM

i have the same symptoms on my wifes Mk3 1,6L(74kW AFT engine).
...i sorted out, that spark remains, but fuel supply cuts off.
"the clicking noise" comes from fuel pump relay, when it turns on.
i suspect it has something to do with the ECU, but i'm still working on it, to find out...
ps. i haven't seen the tachometer jump

**fjsmits** · 18-02-2009,09:51 PM

Have a look at the ignition switch. On mine it appeared that the contacts were worn inside the switch and sometimes made contact and sometimes did not make contact. I replaced it and have not had a problem since.

**Mardus** · 21-03-2009,09:04 PM

problem solved - faulty main relay, its brazing...

**alangolfgti** · 23-03-2009,09:02 AM

Mine was the ignition switch. dealer part £19. dealer mentioned that he had sold 2 that morning, a common failure for the same part used in other models too! To remove the lock assembly you need to remove an adapter for the steering wheel. its meant to pull off but mine has stuck fast so had to grind it off, and back too the dealer for a replacement, £10. all fixed now.