Cabby Info - Ignition System

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Ignition System

Starters

Intermittent starting

Engine will not start

Ignition timing

Spark plug cross-reference

Ignition control unit pin-outs

Starters

Everything you should know about VW starters and solenoids*: http://forums.vwvortex.com/zerothread?id=2359900 .

The above link includes:

How it's made
Upgrading
Replaceable parts
Troubleshooting
- Lots of starter issues are wiring related
- Sometimes it starts, others not
- Starter stays on even when driving or after the car is shut off
- It grinds like a mofo!
- Ok the starter is out, how do I know if it's good?
- Slowwwww cranking
- The starter spins, but doesn't engage the flywheel
Replacing the starter

*Diesel starter is shown/used in that link. Diesel starters contain reduction gear sets and are larger and heavier than gasoline starters.

Intermittent starting

Causes and remedies:

Ignition switch is faulty. Replace ignition switch.
Starter is faulty. Replace starter.
Faulty battery cables and/or electrical connections. Replace battery cables and/or clean/repair electrical connections. Be sure the ground connections are good. Note: Replacing the battery cables is a wise idea whether or not your car is suffering from starting issues.
1990+: Coolant temp sensor (CTS) is faulty. Replace blue CTS.
Cabriolets with automatic transmissions:
- Not starting when hot: Starter is suffering from heat-soak. Install a hot-start relay and be sure the heat shield is in place.
- Intermittent starting: Starter-interlock system is faulty. Replace or bypass the interlock relay.
Fuel pumps are overheating. Replace fuel pumps.
Fuel pump relay is faulty. Replace relay.

Engine will not start

No spark
Faulty/wet distributor cap, rotor, and/or spark plug wires
Weak coil
Faulty ignition switch
Defective Hall sender
Incorrect ignition timing
Engine mechanical failure
Faulty fuel system

Ignition timing

How to set the timing

Spark plugs - cross reference chart

Bosch	Beru	Champion	Denso	NGK
WR7DS¹ (single, silver)	RS35	N8GY	IW20	BPR6EY-11 (#5799)
W7DC WR7DC+ (single, copper)		N9YC	W20EP-U	BP6ES (#7911)
WR7DP (single, platinum)				BPR6ES
W7DTC² (triple, copper)		N9BYC	W20EPB	BP6ET (#1282)

NOTES:

Above chart is a guide only; please verify the part numbers prior to purchasing/installing
¹This plug type is not recommended.
²This plug has been discontinued by Bosch, but is still available at many online retailers.
Firing order: 1-3-4-2
Spark plug gap: 0.028"/0.7mm
Many advise not to waste your money on platinum plugs, while others say that they work better and last longer. By the same token, some say that Bosch is best and that NGK sucks. Engines are like people: each one has its own personality. My '86 JH engine may work best using single platinums while running premium fuel, while your '86 JH may work best using triple coppers while running regular fuel. Plugs are simply trial and error parts; choose the one that works best with your car.

Ignition control unit pin-outs

CIS
Pin	Function	Wire Color
1	Terminal 1 on coil	Green
2	Ground	Brown
3	Terminal 1 on Hall generator (-)	Brown/White
4	Terminal 15 on coil	Black
5	Terminal 3 on Hall generator (+)	Red/Black
6	Terminal 2 on Hall generator	Green/White
Digifant
Pin	Function	Wire Color
1	Terminal 1 on coil	Red/Black
2	Ground	Brown/White
4	Terminal 15 on coil	Black
6	Terminal 25 on Digifant ECU	Green/Black

wtopw

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