VW Golf Mk 4 Diesel PD 130 engine code ASZ... - Intermittent Starting Problem

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Tue 3 Mar 2015 15:50
VW Golf Mk 4 Diesel PD 130 engine code ASZ... - Intermittent Starting Problem - KenC

Hello All,

I wonder if anyone can please suggest a likely explanation for the intermittent starting problem with my low mileage 2003 VW Golf PD 130 Diesel.

The symptoms are as follows,

1. key inserted, turn to first postion all warning light/symbols "on" and sound of fuel pressurising is heard.

2. after few seconds all warning light/symbols" off" except Battery

3. turn key to start position a feight single "click" is heard and nothing else happens, no cranking/starter engagement or other sounds.

4. turn key back to ignition off position ( no warning lamps ) repeat the process and car will start normally and easily.

The battery is relatively new and there is no sign of it not having enough power when cranking,once started it drives normally.

This "Glitch" can happen once every few days or 3/4 times in a row

All opinions very welcome,thank you

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Tue 3 Mar 2015 20:19
VW Golf Mk 4 Diesel PD 130 engine code ASZ... - Intermittent Starting Problem - craig-pd130

Sounds like the starter solenoid is on its way out, that's what's making the clicking sound. The solenoid should engage the starter drive gear with the flywheel, but is not doing so. Any competent garage should be able to check this and replace it for you.

Might also be worth checking the earth strap that runs between the engine and the car body for rust at either connection. A good squirt of WD40 on the connection points is worth a try.

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Wed 4 Mar 2015 14:10
VW Golf Mk 4 Diesel PD 130 engine code ASZ... - Intermittent Starting Problem - KenC

Hi Craig, thank you for your input

yesterday / this morning I have whipped the battery & battery tray out disconnected the earth strap and +ve battery to starter solenoid cable cleaned all connections and refitted.

Went out for a drive car started fine, a series of stops and short journeys in all it started fine 7 times in a row.

On the eighth time it failed to start ( a click and nothing) I turned the ignition key to the off postion and cranked again and it started fine.

I am going to get some tests carried out, I wonder do you happen to know if the solenoid is faulty can it be repaired/overhauled ? or would I have to buy a complete new starter motor, thank you ken

Edited by KenC on 04/03/2015 at 14:10

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Wed 4 Mar 2015 15:01
VW Golf Mk 4 Diesel PD 130 engine code ASZ... - Intermittent Starting Problem - craig-pd130

No idea, I'm afraid :)

But this might help: uk-mkivs.net/topic/230180-mark4-tdi-golf-starter-m.../

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Wed 4 Mar 2015 17:05
VW Golf Mk 4 Diesel PD 130 engine code ASZ... - Intermittent Starting Problem - elekie&a/c doctor

If tests prove that the starter is faulty ,Iwould suggest get a remanufactured unit.Replacing the solenoid on its own may not fix the fault.

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Thu 5 Mar 2015 07:48
VW Golf Mk 4 Diesel PD 130 engine code ASZ... - Intermittent Starting Problem - KenC

Thank you for Craig & Elekie Doc for your advice, I am looking for a local auto electrician or starter motor specialist. Furthermore I am considering removing the starter motor myself and taking it for an overhaul/rebuild.

Thinking through the process of removing the starter motor I am 90%

confident that I can do it, one thing that I am unsure about is how to remove the plastic part on top of the solenoid ( its purpose appears to be a mounting point for a connector and to route cables ) It is about 3" x 2"

I hope this image is visible s284.photobucket.com/user/dovedale54/media/starter...0

apart from smashing it off with a hammer all suggestions welcome :-)

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Thu 5 Mar 2015 08:18
VW Golf Mk 4 Diesel PD 130 engine code ASZ... - Intermittent Starting Problem - elekie&a/c doctor

This plastic part is just a carrier/guide for the wiring connector.It should just unclip from the body of the starter.On a car this old it will probably break as you move it ,but it is not a very important part.Removing the starter on these is not difficult.

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Sat 7 Mar 2015 14:37
VW Golf Mk 4 Diesel PD 130 engine code ASZ... - Intermittent Starting Problem - KenC

Update for anyone interested, I removed the starter ( a valeo make) relatively easy bearing in mind I am a novice with the spanners.

took it to an engineer who rebuilds starters and alternators.

He later contacted me and told me the armature was f*C*XX and it was not a viable rebuild. I purchased a new one from him (£120) and re fitted it, ( ensuring the securing bolts were correctly torqued ) started easily immediately, fingers crossed that will resolve the starting problem, regards K

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