1G No start issue

[wolf20043]

Well, I finally met my match on a problem and have to ask for opinions.

We bought a 91 TSI AWD for $400 a few months ago and it seemed to run pretty good. After about 100 miles, the car started to run crappy, boost gauge (stock) bouncing all over the place, so I pulled the ECU. No problem, it was leaking, so we bought a new one and it fixed the problem.

After a bit, the car started to act like a bad starter. All power works, just wont crank over, just a click. Pulled the battery, had the starter checked, it was good, so we replaced the battery and problem solved. Two days later, same problem. Had the alt checked, bad. Replaced it, problem solved. Another two days, same problem. Checked the battery, good. Checked the starter relay switch, good. Replaced the terminals, problem solved. Same day, same problem. Got the car to the house after messing with some wires and hearing sparking from the harness that holds the battery +/-. Pulled all of the casing off of the harness where we were hearing the arcing, saw the + to the starter solenoid wire had some fringing wires, taped it up, re-installed everything, car starts right up. Went out 1 hour later, SAME FARKING PROBLEM!!!!!!! What the hell else could it be.

No blown fuses, grounds are all good, ECU is fine. I am out of ideas.
Mike

 

[luv2rallye]

The big battery negative cable must go directly from battery minus to the starter casing (install) bolt, nowhere else. Remove this cable both ends, clean terminal and what it attaches to, tighten securely. Also make sure the other battery negative goes to body and is clean (retighten). Measure voltage at starter (on the starter + post, not at battery end of starter cable) when cranking (should be over 11V).