[audifans] 4000s starting issue (no click/crank)

[Huw Powell]

>  I checked the solenoid with a testlamp. lights OK at
> OFF (term50) & lights OK at turn of key to start
> position (term 30).

I think you have that backwards - 30 is the battery (big wire/stud on 
starter) and should always be live.  50 is the circuit energized by the 
key in the "start" position, "from" the switch is one of the small 
wires, and "back" to the fusebox is switched by the solenoid.

Anyway, if you've got a good 12v at the battery terminal and a good 12v 
coming in from the ign switch and nothing happens... need new starter.

>  Seems to be a bad solenoid at this point.

Yes, it does.  Often, the heavy wire going to it from the starter body 
(forgive for not going to get one to look at and describe better) 
corrodes away and is a pain to repair.

> Strange
> though, when I have the key in the half-turn postion,
> the hork hardly makes more than a click noise. The Horn
> fuse is OK.

Let's fix the horn later.

>  Briefly looking through my notes & the "Audi 4000,
> Coupe: 1984-87 Manual", it mentions a groundwire &
> mounting bolts - neither or which i can see (looking
> back from the front of the vehicle).

There are two mounting bolts, one with a nut and one that screws into 
the starter itself from behind.  They are respectively directly below 
and directly above the main starter body.  The starter is grounded by 
its body to the engine block where it mounts.  (or, arguably, by the 
mounting bolts)

> I have it up on
> the standard jack so I guess I need to view from behind
> the right-front tyre. Any tips on RE & RE ?

Yes.  First, put that factory trunk jack out for recycling with the 
aluminum cans.  Pick up a real (small is ok) jack and a pair of 
jackstands.

Disconnect battery ground wire and make sure it can't remake contact. 
Jack up right front corner and support with stand or stands.  Remove RF 
wheel.  At front of solenoid remove the three wires (some only have 
two).  Keep track of which small one goes where if there are two.

Wrestle around to get the lower bolt and nut undone and the upper bolt 
out.  No need to completely pull out the upper one if you can help it. 
Access for the top one is easiest through the wheel well, although you 
won't be able to see it fro the angle you will undo it.  make sure it's 
the right one, as there are other tranny bolts in the neighborhood.

When it's out clean the area where it mounts to the block as that is how 
it is grounded.

Bolt the new (or good used) one in and reconnect wires.  Double check 
wires.  Reconnect battery ground and test before installing wheel and 
lowering car.

> alex v.
> early '86 4000s auto 
> 5-Cyl. 2.2

-- 
Huw Powell

http://www.humanspeakers.com/audi

http://www.humanthoughts.org/