Volkswagen Corrado (1993 year). Manual - part 182

 

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Volkswagen Corrado (1993 year). Manual - part 182

 

 

STARTER 

         1993 ELECTRICAL
         Volkswagen Starters - Bosch

         Volkswagen;  Corrado SLC, Passat

         DESCRIPTION

         Starter is a brush type, series-wound electric motor with an
overrunning clutch. Field frame is enclosed by commutator end frame
and drive bushing, and carries pole shoes and field coils. A splined
armature shaft drive end carries drive assembly.

         TROUBLE SHOOTING

NOTE:    See  TROUBLE SHOOTING - BASIC PROCEDURES article in
         GENERAL INFORMATION.

         ON-VEHICLE TESTING

         STARTER DOES NOT CRANK ENGINE

         1) Ensure battery is fully charged. Make sure electrical and
ground connections are clean and tight. With ignition switch in START
position, measure voltage at spade terminal of starter solenoid.
Reading should be at least 8 volts. If voltage is as specified, check
engine for mechanical problems. If voltage is not as specified, go to
next step.
         2) Measure voltage at ignition switch. If reading is at least
8 volts, check wiring between ignition switch and starter solenoid. If
voltage is not as specified, replace ignition switch.
         3) Measure voltage at field (starter) terminal of starter
solenoid. If reading is 8 volts or more, repair or replace starter. If
reading is less than 8 volts, replace starter solenoid.

NOTE:    On vehicles with automatic transmission, also check
         park/neutral switch.

         STARTER CRANKS TOO SLOWLY

         Ensure engine crankcase is filled with recommended viscosity
oil. Check charging system to ensure battery is fully charged. Make
sure electrical and ground connections are clean and tight. If starter
still turns slowly, repair or replace starter.

         VOLTAGE DROP TEST

         Starter Main Terminal
         Connect a voltmeter between starter main terminal and starter
body. Disconnect ignition coil positive terminal and operate starter.

STARTER 

         Main Starter Case
         Connect a voltmeter between positive battery terminal and
starter motor "M" terminal. With ignition off, operate starter for 2-3
seconds. Battery voltage should be present, then drop to less than one
volt. If voltage is greater than specification, high resistance may be
present in circuit. Go to ACROSS SOLENOID SWITCH test.

         Across Solenoid Switch
         Connect a voltmeter between 2 starter solenoid terminal stud
connections. With ignition disconnected, operate starter for 2-3
seconds and note meter reading. Initially, battery voltage should be
present, then voltage should drop to less than .5 volt. If voltage is
not as specified, check for damaged switch or loose or dirty
connections. If high resistance is present, terminal may be loose or
corroded.

         Ground Return Line
         Connect a voltmeter between battery ground terminal and
starter main housing. With ignition off, operate starter for 2-3
seconds. If ground is okay, voltage reading should be less than .5
volt. If reading is .6 volt or more, high resistance is present in
ground return side of circuit.

         BENCH TESTING

         STARTER SOLENOID

         1) Remove bridge strap connecting solenoid to motor. Check
windings by connecting a 12-volt self-powered test light between
solenoid main terminal STA and solenoid body. If light illuminates,
both windings are satisfactory.
         2) Ensure that contacts open and close satisfactorily by
connecting a 12-volt self-powered test light between starter solenoid
main terminals. Test light should not illuminate.

NOTE:    Step 3) uses a non-powered (standard) test light.

         3) Connect a test light to STARTER terminal of solenoid and
ground. Apply voltage to STA and BAT terminals of solenoid. Solenoid
should be heard to operate as contacts close and test light should
illuminate. When voltage is removed from STA terminal of solenoid,
test light should go out.

         STARTER LOAD (LOCK) TEST

         With starter on test bench, lock starter drive pinion.
Voltmeter should read 4.5 volts and ammeter should read 700-800 amps.

STARTER 

         With starter on test bench, operate starter and check
ammeter, voltage, and RPM. Readings should be within specification.
See STARTER NO-LOAD TEST SPECIFICATIONS table.

STARTER NO-LOAD TEST SPECIFICATIONS TABLE

ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ

Volts               Amps               RPM

11.5  ...........  65-95  ..........  6500

ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ

         REMOVAL & INSTALLATION

         CORRADO SLC & PASSAT

CAUTION:  Failure to use Support Beam (VW 10-222A) and Leg Set (VW
          10-222A/1) may result in misalignment of
          engine/transmission assembly.

         Removal & Installation
         1) Disconnect negative battery cable. Support
engine/transmission assembly with Support Beam (VW 10-222A) and Leg
Set (VW 10-222A/1). See Fig. 1. Remove engine mount bolts. Remove
rubber engine mount lower nut and clamp screw. Remove engine mount.
         2) On Passat, cut and remove starter and alternator wiring
harness tie straps. On all models, disconnect wiring and remove
starter. To install, reverse removal procedure. Tighten starter
mounting bolts/nuts to specification. See TORQUE SPECIFICATIONS table
at end of article.

Fig. 1:  Removing Starter (Corrado SLC, Passat)
Courtesy of Volkswagen United States, Inc.

STARTER 

         For overhaul, see exploded view of typical Bosch starter. See
Fig. 2.

Fig. 2:  Exploded View of Bosch Starter (Typical)
Courtesy of Volkswagen United States, Inc.

 

 

 

 

 

 

 

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