Passat (B5) :: Starter Wouldn't Crank


Aug 13, 2011

So months ago, my wife reported the starter wouldn't crank, but after a few tries it did and the car started right up, no issues since then. I figured she didn't push the clutch in far enough.

Two weeks ago, the car threw a code for the Cam position sensor and was making some funky noises (hard to describe, almost like a rattle inside/beneath the engine) and started bouncing at idle. I replaced that within a few days and cleared the code, but the noise persisted as well as the idle (but not all the time).

Then last week it was still ratting around with no codes, but died on the highway and had to get it towed home. It would turn over, but wouldn't start. After fiddling a while and trying to start it a bunch, it would no longer turn over, so I figured the battery didn't have enough juice. Trying to jump it, I got sparks like you wouldn't believe. I actually started a small fire, and I hooked up the cables correctly too! I checked all the cables, made sure I was doing it correctly and tried again, same thing. So then I researched and saw that can be caused by a failing battery. Sure enough, the battery was 7 years old, so I went and replaced it. Still no start.

A few days later, checking more at home, it had spark, I can hear the fuel pump turn on, timing belt is in good shape, and the throttle is opening (electronically controlled). Still confused I bought a HEX+CAN and here's the results for Engine:

3 Faults Found:
16497 - Intake Air Temp. Sensor (G42): Signal too High
P0113 - 35-10 - - - Intermittent
17951 - Angle Sensor 1 for Throttle Actuator (G187): Signal too Small
P1543 - 35-00 - -
17580 - Angle Sensor 2 for Throttle Actuator (G188) Signal too Low
P1172 - 35-00 - -
Readiness: 0110 1101

So after taking apart the throttle to check it to make sure that it indeed was opening like the vag-com said it was, I put it back together and now the car won't crank. Well, I've been testing it for a while, so I figured the new battery was starting to get low, so I went to jump it and I almost started another little fire. The jumper wires heat up like crazy too. Their is no continuity between the negative and positive terminals on the battery, so I'm not sure what's going on.

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I have a '99 Passat with the 1.8T and auto trans. that does not always crank over, when you go to start it. Most of the time it cranks over and starts just fine, but there are times when you turn the key to the "start" position and nothing happens. Sometimes you have to turn the key back and forth a few times to get it to start and other times just holding the key in the "start" position for a few seconds and it will start.

I've checked the starter and every time that I applied 12 volts to the terminal 50 at the starter, it worked, but if I go back to start it with the key it goes back to random cranking. I removed the ignition switch and bench tested that with an ohmmeter and it works every time. Do I have something going on with the Starter Interlock Relay?

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Two days ago I get in the car to leave work and the same thing happens. You might hear the starter click when you turn the key but nothing else happened. The car was getting power from the battery but that was about it. I tried to jump the car off but still the same thing. I had the car towed to a local Goodyear shop and after looking at it the said it was a problem with the alternator, that needed to be replaced, which also killed a cell in the battery that needed to be replaced also. They said since they are replacing the alternator they might as well replace the belt also.

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Came back and drove away with no issues. When I stopped again about 2 minutes later and shifted to PARK, the starter engaged making it's terrible 'hey stupid, I'm already running' sound. I tried shutting it OFF quickly but it still ran and made it's skinning crawling noise. So I quickly shifted back to DRIVE. All the gears worked fine but PARK and NEUTRAL had the starter engaging. I also could not shut the truck off from DRIVE as the key would not turn.

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I first thought it was a faulty inertia switch or wiring in that vicinity, as at one point after manually tripping and resetting the cutoff switch it would start, UNTIL I put the trim panel back. At this point I think that may have been a coincidence.

I eventually probed the switch and it tests as it should electrically.

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Last Saturday I pulled the relays from behind the radio and cleaned 'em up real nice. Also, just to check another variable I swapped the two that matched.

I'm about ready to change the fuel pump, but I've heard so many people say they did that but the problem was something else. Not only will it costs hundreds of dollars, its cold out and we'll have to drop the tank in the driveway.

In addition to the relay, inertia switch and fuse, I have found some mention of faulty fuel pressure regulators causing issues. I'll pry the vacuum line off in the morning to see if I can detect fuel residue on the vacuum side. (There is some noticeable corrosion on the fuel rail in that area).

I REALLY want to make sure I rule everything else out before spending hours under the truck in freezing weather dropping the tank and changing the sending unit out.

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I do hear the relay clicking behind the radio. (Also, I pulled them again tonight and put a meter to them. With 12V on the primary side, they click and the other side shows continuity on diode check, and about .2 Ohm on resistance mode.)

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Code:
Thursday,10,July,2014,14:01:01:08208
VCDS -- Windows Based VAG/VAS Emulator
VCDS Version: 12.12.2.0
Data version: 20140212

[Code] .....

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[URL]...................

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