Video Update: This is Pathetic
15º F this morning: this is the cranking I got (car had been sitting for 2 days):
By the way, you can't hear it, but I waited until the relay clicked for the GPs, light goes out several seconds prior.
http://www.youtube.com/watch?v=bVPvTcQbpNg
According to the tach, we're talking about well less than 100 rpm here. So we can put to rest that myth that about the pump not injecting fuel below 150 rpm or 250 rpm, or whatever they say
To summarize:
My original starter was squealing, and because the cleaning fix is temporary, I decided to just jump for a new starter at my mileage. I really regret this.
• On June 15, 2008 @ 183,380 miles I replaced the starter with a certified Bosch reman from what was then tdiparts.com. Sent back my old starter as a core return. Always starts immediately in the summer, so it wasn't until the winter of 2008 that I noticed cranking speed was pretty bad in cold weather. I've been trying to get my cranking speed back since. It simply drops off precipitously as temperature drops.
• I thought the Autozone Duralast Gold 94R battery that I had purchased in 2007 @ 173,780 miles was weak, so I replaced it with an EverStart from Wal-Mart in December 2009. Cranking did seem to get slightly better with the new battery, but still not anywhere near 250 or 300 rpm. Just barely made it through last winter, plugged in as much as possible.
• Thought the connections to the starter and to the battery might be corroded or loose. Cleaned and tightened; nothing was found loose either.
• Thought that grounds may have gotten corroded, looked okay, but cleaned all grounds under the battery anyway.
• Thought that grounding strap and power cable to the starter may be corroded (they were visibly corroded), replaced those.
• Thought alternator might be overcharging or undercharging batteries and killing them; haven't ruled out overcharging (was charging at 14.4 volts) but definitely is maintaining battery voltage at 12.4 to 12.5 volts)
• Ruled out excessive static current draw killing batteries.
• Had a fancy Snap-On tool computer check voltage drop and starter amp draw while cranking for an extended period with the pump electronics disconnected: it passed all tests according to that machine.
• Have been considering the unlikely circumstances:
a. maybe the glow plugs are drawing too much power (don't ask me how), and taking a serious chunk out of the battery's reserve before cranking starts.
b. I accidently was delivered a 2.0/1.8t starter, which is 80% weaker than the TDI/VR6 starters.
So: New (reman) starter going in this week, any guesses to the outcome?