Resolved Fwd Motor into Awd Car Starter Problems

[a7xinsane]

Hi guys, I've looked into the issue but nothing I've came across really anwered my question. Okay, little backstory. I'm doing a motor swap. Dropping a fwd 6 bolt motor into my 91 tsi awd. The fwd parts car came with 3 starters 2 of which don't work according to a bench test. So I installed the one that worked but wont line up with the holes on the spacer plate between tranny and block. so I grinded the plate off just where the starter will go so the starter bolts directly to the tranny. I turn the key and no clicking, no grinding, no noise whatsoever. The car did not have any problem with the starting system before I did the swap(but we all know how these things go). Could the starter be wrong and it can't even try to engage? Since I grinded the spacer away would I have to put flat washers in so that the starter can engage? or will I just have to suck it up and rip her back out to put an awd plate in to be sure?

 

[bmxfelon420]

Pretty sure the plate is different. I know that even the 2.4l and 2.0l plates are different so I cant imagine the FWD and AWD ones are the same.

 

[a7xinsane]

FWD and AWD plates are different but my main question is whats going on with my starter at this point. Not shimmed right.. wrong kind of starter.. etc.. But I appreciate the reply!

 

[2gmitsueclipse]

I would look at whether your engine came from an auto or manual. The biggest difference comes from whether or not the starter came from an auto or manual. Aside from that, the correct starter plate is needed to match the starter with the engine/trans configuration.
Starter part numbers:

5spd 90-93.5 md172860
5spd 93.5-94 md172861
auto 90-94 md172860
5spd 95-99 md172860
auto 95-99 md172861

 

[miguelmcv]

Have you remove the starter and test it out of the car to see if it works?

 

[miguelmcv]

Forgot to ask, are you sure you have the trigger wire connected?,,,, you can trigger the starter by adding power to the solenoid directly from the battery to make sure the solenoid is getting power.

 

[a7xinsane]

starter most definitely works outside of the car. Both cars are 91 5 speeds... Trigger wire(black and yellow small one) is hooked up. ive even tried jumping it with it installed and it wont turn whatsoever.

 

[miguelmcv]

Then there has to be several things.

1. The trigger wire is bad not allowing current to get to the solenoid.

2. The positive cable is not hooked up right or is not tigt.

3. The ground cable is not making good contact .

If all this is good then the starter is not good at all

 

[2gmitsueclipse]

Some other things to check are:

• Swapping to your original starter

• Starter relay
  
  
• Neutral Safety Switch

• Alternator fuse

• Mechanical timing

 

[inthemidst]

Do you use the original flywheel I believe the awd and fwd are different size.

 

[a7xinsane]

I was forced to use the original flywheel. the fwd one is bigger and i couldnt mount the tranny up with it on. you guys may be right about a wiring issue but it does work if i hook it up outside the car and ground it, then turn the key she spins right over. Once i put it back in the car i dont even get a clicking noise... Not from the soilenoid, not from the relay, not from anything.... only thing that makes any noise when i turn the key over is the injector relay thing... sorry no correct terminology for that one... But i will resolve this issue this weekend when the motor and tranny come back out. So i can reinstall the clutch that i muffed up putting in... didnt torque to 16 ft/lbs just tightened her up in a star pattern but she wont disengage so back out it comes. i guess ill paint it and swap wiring harnesses too and everything while its back out... Car needs full resto anyways... just no rust so lucked out on that

 

[miguelmcv]

You can't use the fwd flywheel on awd, it will not start, as you said the flywheel is bigger and starter don't align, you will never be able to get it running anles you change to the awd flywheel.

 

[a7xinsane]

I am using the AWD flywheel. Tranny wouldn't mount with the FWD one like I said. Issue is resolved. Turns out that the starters were different for fwd and awd... I feel REALLY stupid.... Gonna drop in an awd starter and I might actually get somewhere haha. Thanks for all the info, as always you guys are great!