Working on an 85 Jetta GL with 1.8L gas, auto trans, ac, 210,000 miles. When we got the car four years ago, it started exactly like it should - get in, turn on the key, wait until the fuel pump stopped buzzing, kick the starter, and the engine started every time (well, not every time until I put a relay into the wire going to the starter solenoid to increase the current enough to overcome the heat swelling problem). About six months ago, I began having trouble starting the car, mostly when it was warm (not hot, not cold). I could always start it, but it required some fluttering of the pedal to get things to catch. I've done a lot of stuff to this car trying to get it into better shape. When it came to me, it pinged badly, and I discovered a previous owner had removed the in-tank fuel pump and not replaced it. Putting one in removed the ping (go figure!). I did a full tune on it last summer: all filters, plugs, wires, cap, rotor, timing, etc. That sure made it run smoother. I discovered that the fifth injector was not injecting, so I replaced the sensor for it, which got it going. I thought I had the problem solved when I did that, but it still proved hard to start. I pulled the four engine injectors and replaced the large and small o-rings and the burned-up ceramic shrouds. While I had the intake manifold off (don't ask) I replaced the oxygen sensor. Now, the car has plenty of zip and moves up through the gears very smoothly; as a matter of fact, it drives almost like it was new. At this point, it starts a lot easier than at its worst, but I still have to flutter the pedal to make sure it will start - otherwise, it will crank forever without catching. It no longer seems to be temperature related. I keep it in a garage at home, but park it outside all day at work. When I get into the 65-degree car in the morning, it won't start without a little pedal flutter. When I go out at the end of the workday and start the 25-degree car, it needs a little pedal flutter to start. I seem to be able to always start the car without incident, but my wife and son have both run the battery down trying to get it going, which is why I'm still pursuing the problem. I have access to a complete shop every Friday night, with all the tools anyone could ever want, so I can check out almost anything anyone suggests (I'm auditing the open shop class offered through the auto mechanics class at the local technical college). So, the question is, what should I go after next? Pat
- posted
17 years ago