Hard to start. Insight needed.

[IslaTurbine]

I've hit a slight hiccup on the removal of the y-cable.

 

Do any of you know how to remove the throttle cable from the throttle body? I have the lug end of the cable released from the barrel, but the cable is inserted into the throttle body with a black plastic clip. I can't figure out how to undo that in order to remove the throttle body completely from the engine.

 

Thanks!

[IslaTurbine]

Well I could never figure it out but I ended up doing this fix without needing to remove the throttle body, intake plenum, and A/C compressor. Saved me a lot of steps and hard work!

[Ahsai]

Yes, I read that's possible on a MkI. So did the cable fix your voltage/start problems?

[IslaTurbine]

Yes, I read that's possible on a MkI. So did the cable fix your voltage/start problems?

Yessir it did! Car shows over 14 volts with no load and even with a heavy load the volts don't go below 13 now. After a drive, I shut down the car and restarted her. The cranking amps seem to be restored, probably due to the battery getting a heathy charge now.

Thanks for all of your help!

[IslaTurbine]

Here's what the old cable looked like.

[Ahsai]

Here's what the old cable looked like.

Yikes! Glad you got it sorted.

 

I start to think we should make this cable replacement mandatory for anyone having any starting and/or charging issues. Gonna save a lot of troubleshooting time :)

[IslaTurbine]

 

 

I start to think we should make this cable replacement mandatory for anyone having any starting and/or charging issues. Gonna save a lot of troubleshooting time :)

 

 

I think you're right.

[Y2K911]

Well I could never figure it out but I ended up doing this fix without needing to remove the throttle body, intake plenum, and A/C compressor. Saved me a lot of steps and hard work!

Isla;

I have got to tackle this same task on my Mk1 (C2 2000).

Would you mind being a bit more explicit about your statement above; ie, how did you manage to thread the cable on the A/C Compressor side?

What minimum # of accessory items did you remove in order to get the job done? Thanks!

Martin

[Ahsai]

Try this trick. It will save you some labor. http://rennlist.com/forums/996-forum/870715-alternator-starter-cable-replacement-simplified.html

 

Basically use hot water to soften the plastic box attached to one end of the cable and remove the box. That will allow the cable to be fished through without moving the a/c compressor and twisting the steering pump reservoir.

Edited April 29, 2015 by Ahsai

[IslaTurbine]

Isla;

I have got to tackle this same task on my Mk1 (C2 2000).

Would you mind being a bit more explicit about your statement above; ie, how did you manage to thread the cable on the A/C Compressor side?

What minimum # of accessory items did you remove in order to get the job done? Thanks!

Martin

Follow Ahsai's link.

I had to remove the airbox, serpentine belt, and alternator. Removing the throttle body would have given a little better of a sight line to the cable end on the starter, but it wasnt absolutely necessary in my case.

[Y2K911]

Thanks for the quick reply, IslaTurbine! Merci!

[IslaTurbine]

Good luck!

[injurylawyer]

Here's what the old cable looked like.

 

What do you think did that to your cable? 'farmer boy' indicated that he had a defective starter that he replaced and looking at the photo of the terminal you posted, looks to be the end at the starter. Do you think your starter has a short that caused that? Corrosion? Engine Temperature?

[IslaTurbine]

I wish I knew. From all the pics I've seen, the corrosion on mine looks consistent with most of the other failed cables out there. It's likely a heat/crappy cable quality issue.

[injurylawyer]

I wish I knew. From all the pics I've seen, the corrosion on mine looks consistent with most of the other failed cables out there. It's likely a heat/crappy cable quality issue.

Wow!

 

As an aside, I read that a faulty starting circuit or starter motor can even cause a host of CEL issues as well (P0341)...the corrosion on that cable would explain alot...

 

Hope it does not happen again for you!

[Ahsai]

I still don't understand how it can corrode so badly as if it was attacked by salt water or something acidic. The lug locates in mid-air right above the engine case. I wonder if there's any corrosive vapor in that area but I can't think of any such source.