Intro and a few q's

[Corderoy]

Transmission installed.

Much easier with the suspension out of the way.

From what I read 3% moly disulphide grease will do for the cv housing. I've got some Penrite here so I'll whack a bit in there on spec.

Can't find specific info on final drive oil or changing it.

Anyone done it?

[Golf Loon]

Final drive shares its oil with the transmission.

Yup, grease up the hubs and you`ll be fine.

[Corderoy]

Final drive shares its oil with the transmission.

Yup, grease up the hubs and you`ll be fine.

Thanks again

You've probably caught on that I haven't had much experience with FWD auto's... actually as I rapidly approach my sixth decade, this is the first one, lol.

[Golf Loon]

All good mate, next one will be easier.

[Corderoy]

Bits turned up today.... thanks Matt, great service and prices.

It's 90% finished.

Just got to finish securing wiring harnesses (spent a fair bit of time replacing the insulation on the harnesses), spark plugs/leads, change oils and filters, front end/radiator back on and voila!

Providing it actually all works I'll take it in on Tues and get the aircon guy to do his thing.

[Corderoy]

So, I've come to an agonisingly slow halt...

History:

Ignition/starting was operating normally when it was parked.
Has been parked without starting for six months.

Recently fitted reco head and new head gasket kit.
Recently fitted second hand "CFK" auto transmission.
Recently fitted thermo fan sensor/switch.

Car back together except for headlights, grill, front bar.

Problem: Car won't start.

Symptom: No power from ignition switch to starter (tested with test lamp).
Nothing happens at the starter when the ign switch is turned to "start" (with foot on brake pedal). No solenoid clunk, whirring etc.

Troubleshooting:
Checked all engine bay wiring/connectors - ok (can't see any missed)
Fuses checked - ok
Starter removed and bench tested - ok
Flywheel manually rotates - yes

My Haynes does not have an auto trans section so I'm really flying blind with regard to the auto trans detent switch. I assume that the detent switch on an auto would cut power from the ign switch to the starter?

From what I can glean on the internet the Cordoba has a "Multifunction Switch"
This is the MFS on mine:



I removed this switch and had a play with the two plungers. They operate something in the "carby" (or whatever it's called).
When I press the MFS plungers (ign 'on') there is also an audible "clunk" which can also be felt through the T-bar.

I have a spare MFS and harness and both do the same thing.

My question is:
Is this switch also the trans detent switch or is there another switch for that function?

I haven't checked the ignition switch or relay as there was no prior problem with starting.

I've got a feeling the problem is to do with the auto detent switch but I'm unsure what to do next.

Any clues?

Thanks/

[Golf Loon]

It should be in the shifter. Check that the cable is adjusted correctly at the gearbox end and it moves fully forward in the shifter box inside the car.

I`d turn the ignition to on with the reds on on the dash.

Then with the froint wheels off the ground, hotwire the starter with a jumperwire from the big terminal to the small and see if the thing starts.

There is a relay attached to the fusebox that controls the autolockout. A jumper wire there will defeat it too.

My money is on the cables being bent or incorrecltly adjusted so the car thinks its in D and wont start.

Try it in N and a notch either side.

[Corderoy]

I've had a chance to troubleshoot a bit more...

I was happy with the gear selector/selection etc but couldn't figure out the no start.

Decided to order an ignition switch as nothing else made much sense.

Bought a new battery for it, connected it up and hot-wired it at the starter motor.... and away she went.
I'd prev been trying to start it with jumper leads as the terminals on the battery I was using were around the wrong way and leads wouldn't reach.

She runs but it rattles - I guess the hydraulic lifters should have been soaked in oil prior to installation?

THEN I looked a few posts down and saw aerohydro's post regarding their ignition switch. I tried lifting mine whilst turning and bugger me it works, lol.

At least the ignition switch is proven as the prob - I rang my daughter (car's ex-owner) and asked her if she'd had any trouble starting it...."oh, I had to jiggle the key sometimes..." doh!

My next problem (yes, there is now something else, lol) is that because of the remote starting I'd neglected to turn the ignition off whilst I topped up the engine and transmission oil (and mopped up the Dexron I'd spilt).

When I disposed of the rags I could smell something burning.
I disconnected the battery and found that the coil was extremely hot - hot enough to melt part of the plastic around the bottom of it.

Is that what happens on these if you leave the ignition on for five minutes or have I got another problem?

[Corderoy]

Except for fitting the new ignition switch (thanks again, Matt) she's all done

New (used) trans didn't want to play to start off with.... slow to change up/down but a good thrashing on a quiet road fixed it.
For a while I thought I was going to have to do a Basil Fawlty and thrash it with a stick but it came to its senses just in time.

I got a second hand coil (I guess you guys aren't surprised that VW wanted $260!!) which has been modified.
Whoever did the mod has used the original "control unit" and connected that to a Bosch coil. I guess that they were either stuck and had to do it or worked out that it's a lot cheaper to replace a Bosch unit than a "VW" unit.

I'll take a pic if anyone is interested in a look.

All in all an interesting exercise. I must admit that I put off working on it for those six months because it just looked so complex but having had it apart it's actually not too difficult to work on.

Sincere thanks for the assistance along the way, guys. I probably would have waded my way through it but there's no doubt that it would have been a lot more difficult and even more expensive

[Cupra]

good work, hope it behaves its self for you.