1976 2L Kombi going beautifully ... then won't start today

Discussion in 'Fuel System & Electrics' started by Micky O, Jan 3, 2018.

  1. Micky O

    Micky O Member

    Messages:
    73
    Location:
    Blue Mountains
    Yes coil! (Ta I now know the difference). Also the leads were old and cracked. All are now replaced and the bus is going like new again. Mikki down at Indian Automotive had the stuff in stock.
     
  2. Mordred

    Mordred Super Moderator Staff Member

    Messages:
    2,583
    Location:
    Penna, Hobart
    I should have thought too, and thanks to Bert for mentioning it, a solenoid is also the unit on the side of the starter motor that uses the coil to operate a lever to engage the starter.

    Sounds like you got it anyway.

    Adrian
     
  3. Micky O

    Micky O Member

    Messages:
    73
    Location:
    Blue Mountains
    Well it's never that simple is it?

    The brand new Bosch GT40 coil failed after 2 days. It totally blew out through the terminal where the dizzy lead goes, spewing fluid out. In fact, in spectacular fashion it blew pressurised fluid all the way through the dizzy lead so that both ends of the lead got popped off! The only advice I have so far is that this can happen when someone accidentally leaves the ignition on for a long time, which didn't happen.

    Anyway, I managed to source a replacement Beru coil on a Saturday afternoon. The new coil does feel quite hot after a drive, but I would have thought that was normal, which is why they fill them with oil. It's not so hot that it is uncomfortable to hold with your bare hand.

    Any ideas folks? Is it due to some kind of overheating? Or was it just an unlucky dud coil?

    Micky
     
  4. lachie

    lachie Member

    Messages:
    160
    Location:
    terranora
    seems peculiar that 2 coils fail so quickly!
    Worth taking it back to indian automotive - check that the ignition is actually turning off, and in the mean time maybe drop a battery lead when you're not driving to protect your new coil.
     
  5. Micky O

    Micky O Member

    Messages:
    73
    Location:
    Blue Mountains
    Well it turned out that the first coil was at least 20 years old. It's the new Bosch coil self-destructing that is most peculiar. Yes, I will be disconnecting things when not driving until I know more.

    But there IS something funny going on with the electrics. Once or twice when I tried to start the ignition, instead of starting up there is a click and everything just shuts down, no dash lights or anything. I then switch off ignition, go around the back and jiggle the earth strap and the earth connection on the battery and every time it's fixed and it starts up fine. I will definitely replace that earth strap ASAP (though it beats me why a thick metal braided wire would ever fail :confused:) and the battery might be getting old so I'll get it tested. But I suspect this is separate to the coil issue...
     
  6. cbus

    cbus Well-Known Member

    Messages:
    10,444
    Location:
    sunshine coast
    Symptoms match a bad connection/ earth.
    Typical for braided earth straps to exhibit problems due to small amount of corrosion even though there is plenty if braid.
    Clean all contact surfaces of paint etc. Run a new cable. Insulated now most common available.
    Spray with some lanolin / vaseline or other muck to prevent corrosion on connections. WD 40 doesn't last.

    Start with battery and starter cables. Replace earth strap if its a braided one. Ensure colour coding prevents mistakes. Many kombis have batteries with incorrect terminal orientation.
    Dont overtighten group connection on starter solenoid lest you crack the cap.
    Clean all connections with scourer or similarand wipe clean.
    Gearbox to body strap. Renew.
    Plug connections to ignition switch if symptoms persist.

    Multimer across coil + to engine bolt( - ) should show no V ( maybe fraction of a V ) with ign turned off.
    If test is as described don't be concerned about isolating battery unless it is discharging at rest.
    Guess is a dud coil from a 3rd world country. Impressive fail.

    Possible that the previous issue was low voltage to coil or a sad coil. Thus giving a poor spark that then had losses due to failing insulation on HT leads.
    Test original coil. It may still be ok.

    New battery may be a consideration.
    If it is failing you won't squeeze much more life out of it.
    Biggest / best that fits is good. Gives bigger margin if chasing other starting issues at some stage.

    Normal for coil to be quite warm as you describe when operating.
     
    Last edited: Jan 7, 2018
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  7. Micky O

    Micky O Member

    Messages:
    73
    Location:
    Blue Mountains
    Thanks cbus. That right there is a works program for the next couple of days.
     
  8. Kai

    Kai Well-Known Member

    Messages:
    4,646
    Location:
    Eastlakes, NSW
    do not use an oil filled coil like a GT40, Epoxy filled all the way.
     
    David H likes this.
  9. Micky O

    Micky O Member

    Messages:
    73
    Location:
    Blue Mountains
    UPDATE: replaced the earth strap and tidied up a few of those wires and connections to the coil, and blammo everything is going absolutely splendiferously. Well, until the next thing... :rolleyes:

    But how's this! As an added bonus - ??which may or may not be related?? - the fuel gauge seems to have awoken from its prevously semi-comatose state and now shows a generally consistent indication of the actual quantity of fuel in the tank.:D:confused::D
     
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  10. melissa

    melissa Administrator Staff Member

    Messages:
    14,364
    Location:
    Newcastle NSW
    Nice work :)
     
  11. cbus

    cbus Well-Known Member

    Messages:
    10,444
    Location:
    sunshine coast
    'Mazing what a bit of housekeeping can achieve ;)
     
  12. Barry

    Barry Well-Known Member

    Messages:
    2,156
    Location:
    Abbotsford NSW
    Gotta be related to the earth strap

    Well done
     
    oldman likes this.
  13. oldman

    oldman Super Moderator Staff Member

    Messages:
    7,599
    Location:
    Avalon Beach NSW
    Earth strap, or its condition/contact to body, is often overlooked when diagnosing electrical issues.....
    Well done.....every time you poke your head in the engine bay & tidy something up, you learn something valuable.
    Cheers,
    Mark
     
    evan&janine likes this.
  14. syncro

    syncro Well-Known Member

    Messages:
    8,794
    Location:
    Southern Highlands
    Here's a saying for new Kombi owners. "If it looks shit, it probably is. Fix it."
     
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  15. evan&janine

    evan&janine Active Member

    Messages:
    174
    Location:
    chambers flat
    Kai, what are the epoxy coils. Looking to move my onto retirement as spare.
    Regards Evan.
     
  16. Barry

    Barry Well-Known Member

    Messages:
    2,156
    Location:
    Abbotsford NSW
    upload_2018-2-14_9-36-51.png
     
  17. evan&janine

    evan&janine Active Member

    Messages:
    174
    Location:
    chambers flat
    Thanks Barry, just left mechanic and coil sadly has gone beyond y b d. Timely reference ,cheers.
     
  18. Kai

    Kai Well-Known Member

    Messages:
    4,646
    Location:
    Eastlakes, NSW
    The liquid inside the coil - i have found that oil filled coils tend to break down and leak, especially when inverted on a 1600 fan shroud. Epoxy more durable in hotter and rugged environments.

    Only use the pertronix coil if you have a pertronix ignitor fitted.

    standard coil epoxy filled- https://www.justkampers.com.au/043-...or-all-12v-vw-beetle-t2-split-and-t2-bay.html
    Pertronix part number is 40611.
     
    Last edited: Feb 14, 2018
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