slow cranking starter after rebuild

[kaisersolsay]

Hi guys,

Just finished a rebuild on my brothers 2001 1.8T A4. He had bent the exhaust values.

When trying to start her up I notice that the starter is turning really slowly despite the battery being freshly charged. I've even tried it with jump leads but still very slow. It doesn't give the normal 'car turning over trying to start noise' either, instead it just sounds like its slowly spinning the crank and pistons round....which its obviously doing. I have checked the plugs and they are sparking and wet with fuel.

Have I wired the starter back up correctly? There are 2 thick wires, a red and a black. From what I remember one is from the battery (red) and the other from the alternator (black) and they both bolt onto the same place secured with the 13mm bolt. The smaller red connector then pushes onto the tab beneath.

During cranking on one occasion there was a slight puff of smoke that came from the starter location?????!!

I can only think I have the wires in the wrong place.

Anyone remember how to wire it up??!

[kenney]

I don't think it's possible to wire the starter wrongly,i think maybe you have a poor earth somewhere

[kaisersolsay]

Ok, I'll check. Just to be sure, there are only 3 wired connections right? Alternator (Black) Battery Live (red) Trigger Live (small red) Where is the earth?

[kenney]

That is correct There are 2 main earth wires, from the battery to the chassis,and the other from the chassis to the engine

[kaisersolsay]

Is there an earth from the starter?

[kenney]

No,I think you will find the engine- chassis earth is on one of the gearbox screws.The starter is earthed by way of the block.What might be a good idea since you have had the engine apart,is to make sure it turns easy by hand

[kaisersolsay]

Great thanks. There is a black cable with a mounting bracket floating around the
back on the block resting on the gearbox. I was just being lazy and hadn't secured it.
Could this be the main chassis-engine earth?

[kenney]

possible

[kaisersolsay]

OK, I've secured the rear bracket but unfortunately the starter is still cranking over very slowly.

Anyone got any other ideas?

[kenney]

Still think you have a poor earth somewhere,if the starter was ok before the overhauling,and does the engine turn easy by hand?