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Discussion Starter #1
I have a starting problem I hope someone recognises and can perhaps point me in the right direction.

My wifes beetle a 1.6 petrol convertable late 2004 is having intermittent starting issues. Its been to a VW "specialist" once who said they couldn't fault it.

When in problem mode the symptoms are as follows:

Window wont drop down, no dash lights, no crank, the car appears completely dead. The only electricals which work in this condition are the side lights, the radio, the boot and fuel cap release and the red door puddle lights.

I have replaced the battery and it reads 12.64V the ground is clean and reads 12.63 to the engine block. I have replaced the ignition switch and cleaned the ground under the battery. The 2key fobs both have new batteries.

It seems to come back to life randomly yesterday I kept pressing the unlock, and it came back to life, other times it has been wiggling the key, opening the fuse cover etc.

Could it be bad relay?, dodggy ground? or the ECU something else?
 

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Discussion Starter #2
Yesterday whilst it was playing dead I swapped the ecu and there was no change, this morning it is working again with old ecu. grrrr
 

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It sounds like there is still power some places when it is not working. Maybe you could isolate it further by checking which fuses still have power when it is playing dead. Remove them 1 by 1 and use a voltmeter or test light to check the fuse terminals. 1 of the terminals will have power if the circuit is live. Do this with the ignition both off and on.
 

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Discussion Starter #5
Thanks red99 I will try that the next time there is no sign of life, all is working today.

Billy I read your thread which prompted me to replace the ignition switch but when I took the plug off I was slightly dissapointed to find no signs of overheating or melting.

Is it possible a bad instument cluster could have the effect of cutting power to the ignition etc intermittently?

I have an auto electrician comming a week today hopefully it will be in a state of not working when he sees it.

thanks for your help
 

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Hmm, that is a good question; I know I had a bad speedo cluster, that intermittently would cause the Immobilizer to come on (causing a no start condition) but the starter motor, would still still turn over the engine.

My other thought about your situation; is a progressively failing starter motor, mine intermittently wouldn't turn over (maybe it spun on a bad section of the armature or the solenoid was sticking?) and eventually started smoking and then, stopped working at all! That theory; doesn't explain the lack of lights and other accessories not working however. I guess, you could test the starter motor and see if it is still good. Definitely, electrical related but you just need to track down the cause. Let us know; what the electrical specialist find out and we can go from there.


Sent from AutoGuide.com Free App
 

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Discussion Starter #7
Ive had it scanned twice now the problem persists. The auto eletrician suggested an ignition relay and possible bad ecu or instument cluster?

I went to check the relays with the idea of replacing the load recution relay and the power supply relay as I cant find an "ignition" relay.

The relay in lower position 2 "load reduction" relay was a 100 relay as expected. However the relay in the upper position 12 was a 53 multipurpose relay instead of a 109 relay?

The car is a manual 1.6 soft top on a 54 plate. Does anyone know if the relay in position 12 should be a 109 relay on this model?
 

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Unfortunately, our USA spec vehicles did not come with the 1.6l and are LHD. Our service manuals; will not have correct info for your car. So you would need another member with the same car, to help or look up the info in a UK spec service manual like Haynes or VW's Erwin online subscription service.

Bob Henderson
VW Beetle Service and Repair Manual (Haynes Service and Repair Manuals)
ISBN-100857336541

Description:
Covers: April 1999 to 2007 (T to 57 ref) Petrol and Diesel.
Hatchback (plus major mechanical features of Cabriolet), inc. special/limited editions. Does NOT cover Tiptronic transmission Petrol: 1.4 litre (1390cc), 1.6 litre (1595cc), 1.8 litre (1781cc) turbo & 2.0 litre (1984cc). Does NOT cover 2.3 litre V5 engine. Diesel: 1.9 litre (1896cc) turbo, inc. PD Please also note that this manual has a soft (paperback) cover.

These are very affordable manuals and you can find new and cheap used versions of this manual; on sites like Amazon UK. Keep in mind; these are basic manuals and geared towards the home mechanic.

https://www.google.com/search?q=ISBN-10 0857336541+ISBN-13&ie=UTF-8&oe=UTF-8&hl=en-us&client=safari#hl=en-us&q=ISBN-10 0857336541+amazon

As for Erwin; you can pay for one day access and download all the manuals for your car, in .pdf format, which you can access later on your computer. These manuals, are geared toward the dealership VW factory service techs; very detailed and provide most of the info, you could need for repairs.

http://www.volkswagen.co.uk/need-help/owners/Erwin
 
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