VW Golf 1.9TDi (1996) cutting out - suspect electrical fault

VW Golf 1.9TDi (1996)... About a year ago, the car developed an
intermittent electrical fault. Driving along or stopped and idling,
the engine just cuts out entirely. Still turns. No unexpected
noises. Ignition coil light and speedo stop working. Other
electricals appear to be ok (lights, radio, hazards, etc). After a
period between a few seconds and 5 minutes, the ignition coil light
lights up again, and the engine restarts. The problem is getting more
and more frequent and frustrating on an otherwise good car. A year
ago, I took it to a vehicle electrical specialist, but the problem
didn’t manifest and they couldn’t find anything... any ideas?

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Thread archive: http://www.AutoBoardz.com/VW-Golf-9T...ict248954.html

In rec.autos.makers.vw.watercooled, peterski wrote:

>VW Golf 1.9TDi (1996)... About a year ago, the car developed an
>intermittent electrical fault. Driving along or stopped and idling,
>the engine just cuts out entirely. Still turns. No unexpected
>noises. Ignition coil light and speedo stop working. Other
>electricals appear to be ok (lights, radio, hazards, etc). After a
>period between a few seconds and 5 minutes, the ignition coil light
>lights up again, and the engine restarts. The problem is getting more
>and more frequent and frustrating on an otherwise good car. A year
>ago, I took it to a vehicle electrical specialist, but the problem
>didn’t manifest and they couldn’t find anything... any ideas?

You could try connecting an extra ground wire between the engine and
the frame. What is the ignition coil light? I had a car where that
got rid of some weird symptoms.

I assume you are talking about the glow plug light.

Next time it cuts out jump straight power to the shutoff valve on the top of
the injection pump & see if it starts.

Craig

"Tom's VR6" > wrote in message
...
> In rec.autos.makers.vw.watercooled, peterski wrote:
>
>>VW Golf 1.9TDi (1996)... About a year ago, the car developed an
>>intermittent electrical fault. Driving along or stopped and idling,
>>the engine just cuts out entirely. Still turns. No unexpected
>>noises. Ignition coil light and speedo stop working. Other
>>electricals appear to be ok (lights, radio, hazards, etc). After a
>>period between a few seconds and 5 minutes, the ignition coil light
>>lights up again, and the engine restarts. The problem is getting more
>>and more frequent and frustrating on an otherwise good car. A year
>>ago, I took it to a vehicle electrical specialist, but the problem
>>didn't manifest and they couldn't find anything... any ideas?
>
> You could try connecting an extra ground wire between the engine and
> the frame. What is the ignition coil light? I had a car where that
> got rid of some weird symptoms.

Is it just like you turn the ign off?
It could be the ign switch or possibly a relay.
BUT since you say the engine shuts off and it takes some time for the
ignition coil light to light up (are you referring to all of the lights in
the dash?) that is why I suspect the ign switch.

Or it could be something very costly and time consuming to repair so maybe
you should sell that TDi to me! <g>
No it should be something simple to repair and it is a matter of monitoring
the power to the different systems. ;-)

later,
One out of many daves

"Craig" > wrote in message
...
>I assume you are talking about the glow plug light.
>
> Next time it cuts out jump straight power to the shutoff valve on the top
> of the injection pump & see if it starts.
>
> Craig
>
> "Tom's VR6" > wrote in message
> ...
>> In rec.autos.makers.vw.watercooled, peterski wrote:
>>
>>>VW Golf 1.9TDi (1996)... About a year ago, the car developed an
>>>intermittent electrical fault. Driving along or stopped and idling,
>>>the engine just cuts out entirely. Still turns. No unexpected
>>>noises. Ignition coil light and speedo stop working. Other
>>>electricals appear to be ok (lights, radio, hazards, etc). After a
>>>period between a few seconds and 5 minutes, the ignition coil light
>>>lights up again, and the engine restarts. The problem is getting more
>>>and more frequent and frustrating on an otherwise good car. A year
>>>ago, I took it to a vehicle electrical specialist, but the problem
>>>didn't manifest and they couldn't find anything... any ideas?
>>
>> You could try connecting an extra ground wire between the engine and
>> the frame. What is the ignition coil light? I had a car where that
>> got rid of some weird symptoms.
>

On Sep 19, 1:40*pm, "One out of many daves"
> wrote:
> Is it just like you turn the ign off?
> It could be the ign switch or possibly a relay.
> BUT since you say the engine shuts off and it takes some time for the
> ignition coil light to light up (are you referring to all of the lights in
> the dash?) that is why I suspect the ign switch.
>
> Or it could be something very costly and time consuming to repair so maybe
> you should sell that TDi to me! *<g>
> No it should be something simple to repair and it is a matter of monitoring
> the power to the different systems. *;-)
>
> later,
> One out of many daves
>
> "Craig" > wrote in message
>
> ...
>
> >I assume you are talking about the glow plug light.
>
> > Next time it cuts out jump straight power to the shutoff valve on the top
> > of the injection pump & see if it starts.
>
> > Craig
>
> > "Tom's VR6" > wrote in message
> .. .
> >> In rec.autos.makers.vw.watercooled, peterski wrote:
>
> >>>VW Golf 1.9TDi (1996)... About a year ago, the car developed an
> >>>intermittent electrical fault. *Driving along or stopped and idling,
> >>>the engine just cuts out entirely. *Still turns. *No unexpected
> >>>noises. *Ignition coil light and speedo stop working. *Other
> >>>electricals appear to be ok (lights, radio, hazards, etc). * After a
> >>>period between a few seconds and 5 minutes, the ignition coil light
> >>>lights up again, and the engine restarts. *The problem is getting more
> >>>and more frequent and frustrating on an otherwise good car. *A year
> >>>ago, I took it to a vehicle electrical specialist, but the problem
> >>>didn't manifest and they couldn't find anything... any ideas?
>
> >> You could try connecting an extra ground wire between the engine and
> >> the frame. What is the ignition coil light? I had a car where that
> >> got rid of some weird symptoms.


Don't know if you still have this problem, but I had an almost
identical problem with my 1996 Tdi Estate which started (very
infrequently) about a year ago, but recently got much worse - it would
cut out after a couple of miles almost every trip, although once
warmed up the car would be fine.

Turns out it was a power relay (labelled 109) for the ECU, which is
found just above the fuse rack (in the driver's footwell). Took it
out and prised the cover off, and all the soldered joints were broken
or very dodgy. After a quick resolder, the car is now fine, but I
intend to get a new one from VW as a proper replacement. Apparently
this is a known fault and VW upgraded the relay in later models. The
old one (which I have) is black, the new one is grey.

On Oct 30, 6:26*pm, Tim Prosser > wrote:
> On Sep 19, 1:40*pm, "One out of many daves"
>
>
>
>
>
> > wrote:
> > Is it just like you turn the ign off?
> > It could be the ign switch or possibly a relay.
> > BUT since you say the engine shuts off and it takes some time for the
> > ignition coil light to light up (are you referring to all of the lights in
> > the dash?) that is why I suspect the ign switch.
>
> > Or it could be something very costly and time consuming to repair so maybe
> > you should sell that TDi to me! *<g>
> > No it should be something simple to repair and it is a matter of monitoring
> > the power to the different systems. *;-)
>
> > later,
> > One out of many daves
>
> > "Craig" > wrote in message
>
> ...
>
> > >I assume you are talking about the glow plug light.
>
> > > Next time it cuts out jump straight power to the shutoff valve on the top
> > > of the injection pump & see if it starts.
>
> > > Craig
>
> > > "Tom's VR6" > wrote in message
> > .. .
> > >> In rec.autos.makers.vw.watercooled, peterski wrote:
>
> > >>>VW Golf 1.9TDi (1996)... About a year ago, the car developed an
> > >>>intermittent electrical fault. *Driving along or stopped and idling,
> > >>>the engine just cuts out entirely. *Still turns. *No unexpected
> > >>>noises. *Ignition coil light and speedo stop working. *Other
> > >>>electricals appear to be ok (lights, radio, hazards, etc). * After a
> > >>>period between a few seconds and 5 minutes, the ignition coil light
> > >>>lights up again, and the engine restarts. *The problem is getting more
> > >>>and more frequent and frustrating on an otherwise good car. *A year
> > >>>ago, I took it to a vehicle electrical specialist, but the problem
> > >>>didn't manifest and they couldn't find anything... any ideas?
>
> > >> You could try connecting an extra ground wire between the engine and
> > >> the frame. What is the ignition coil light? I had a car where that
> > >> got rid of some weird symptoms.
>
> Don't know if you still have this problem, but I had an almost
> identical problem with my 1996 Tdi Estate which started (very
> infrequently) about a year ago, but recently got much worse - it would
> cut out after a couple of miles almost every trip, although once
> warmed up the car would be fine.
>
> Turns out it was a power relay (labelled 109) for the ECU, which is
> found just above the fuse rack (in the driver's footwell). *Took it
> out and prised the cover off, and all the soldered joints were broken
> or very dodgy. *After a quick resolder, the car is now fine, but I
> intend to get a new one from VW as a proper replacement. *Apparently
> this is a known fault and VW upgraded the relay in later models. *The
> old one (which I have) is black, the new one is grey.- Hide quoted text -
>
> - Show quoted text -

It seems that relay #109 is known for problems in TDI's. Some
owners even carry a spare with them. I have not had a problem myself
and I don't carry a spare, but the description that could be the
problem.

Thanks everyone for your suggestions. It was that Relay 109 problem!
Cost £13 to buy replacement. And yes - the faulty one was the black
"made in Tunisia" version, with absolutely no visible cracking or
broken solder etc in the relay. I’ve now installed the new grey one,
and the car runs a charm again.
Happy motoring everyone.

"peterski" wrote:
> VW Golf 1.9TDi (1996)... About a year ago, the car developed
> an intermittent electrical fault. Driving along or stopped
> and idling, the engine just cuts out entirely. Still turns.
> No unexpected noises. Ignition coil light and speedo stop
> working. Other electricals appear to be ok (lights, radio,
> hazards, etc). After a period between a few seconds and 5
> minutes, the ignition coil light lights up again, and the
> engine restarts. The problem is getting more and more
> frequent and frustrating on an otherwise good car. A year
> ago, I took it to a vehicle electrical specialist, but the
> problem didn't manifest and they couldn't find anything... any
> ideas?