odd no start issue

[undecided]

So, I'll start by saying I've learned a wealth of useful information from everyone here. Now I've found a problem that I haven't been able to figure out. I read the "trouble shooting - Car Won't Start" threads, to no avail. So here's the problem. This morning, I put on a new glow plug harness, replacing the old harness, which had been cut off. Now my car is not starting; it cranks, but will not turn over. I've even gone so far as to take the new glow plug harness off, with no success. All the regular lights and noises are still working, the glow plug light works; however, when I go to crank the car, the fuel gauge does not register (currently at a full tank), and the odometer and clock go out and the clock re-sets to the default "12:00".

None of these issues occurred prior to installing the new glow plug harness...

As a side note, if anyone is replacing their harness, I've found that a bobby pin with the rubber ends taken off works perfectly for removing the old wires from the main harness. Just push the two ends into the small slots and the clips pull right out.

 

[TonyJetta]

Try replacing relay 109. Common electrical issue.

Tony

 

[undecided]

I plan on it. I was curious though, with the lights on the dash working, would the relay be the issue? It is my understanding that if it were the relay 109, the car would act as if there was no power to anything. Could I have 'tripped' something while replacing the harness? I know the relay is the old black style and needs to be changed so hopefully it will be the cure. While doing all of this I also noticed the inner ring on the main harness is not holding everything together as it should, it seems to be falling apart. Does anyone know if I can replace the inner ring or if I would need to replace the entire harness. I have tried to find some sort of replacement, but other than a junk yard ( which is not an option where I live ) I can't seem to find anything.

 

[Seatman]

I think it might be more to do with the wiring in the engine bay myself, might be worth checking the earths etc and seeing if there's one loose or broken. My experience of the 109 is no glow plug light, you could take it out and tap it off the ground a couple of times, it's worked for me and I'm still using the same dodgy one a year on lol. You could also check the wires going to the pump, the big plug down there, maybe pull it apart and plug it back in a couple of times. Also check all the fuses incase something got shorted out, did you have the battery disconnected? If so you could double check the connections on it and any wires around there too as well as the fuses on top.

 

[G60ING]

I agree this sounds like a grounding or main power cable issue. Clean and tighten the battery connections, clean and tighten the ground strap that goes to the chassis and engine. Clean and tighten the positive battery connection at the starter. Also clean and tighten the ground wires on the bracket on the side of the head near the big cannon plug with the glowplug wires.

 

[undecided]

I was thinking I had somehow messed up a wire in the bay while doing all of this. I'll be checking all of the grounds today, especially the one on the bracket near the cannon plug. This seems to be the most logical since that is where I was working. Thanks again guys for the helpful input.

 

[undecided]

I have now found that if I disconnect the cannon plug the car starts and then immediately shuts off. With the cannon plug connected it just cranks but will not start. Any ideas what this may mean?

 

[undecided]

Problem solved! Turns out the cannon plug wasn't seating all the way due to the coupling being cracked. I feel a little silly not figuring it out sooner. Nice thing is I talked with Josh at Austin Veedub and have a replacement on the way. ( at a great price too ) Thanks again for all the input guys.

 

[G60ING]

yeah its a pricey part, I replaced one this past spring. I hope its new. 13year old plastic is brittle no matter what after 150k miles of heat cycles.

 

[undecided]

I was able to get one used but in great shape, much better than the one on it to begin with. The original did last for 229,384 miles though and probably longer if I hadn't fooled around with it. Just a note to anyone who is looking or thinking of replacing theirs, I was told that there's only 10 of these left in country. New ones that is. Volkswagen parts department is asking $90 plus tax, I found it at 1stVWparts for $65. I hate to see what they'll be going for used when none are left. I think I got a good deal on the used unit from Austin Veedub. They're good guys out there.

 

[G60ING]

yeah I think I chose to pay $80 at my local dealership and avoid the shipping. My local dealer gets parts in 2 days with no shipping costs.

 

[mrorganic77]

Cannon plug

Problem solved! Turns out the cannon plug wasn't seating all the way due to the coupling being cracked. I feel a little silly not figuring it out sooner. Nice thing is I talked with Josh at Austin Veedub and have a replacement on the way. ( at a great price too ) Thanks again for all the input guys.

What and where is the Cannon plug located? Where is source that i could order one of the few remaining.

My Passat will not start. At about 50 degrees it will not start and sends no power to the glow plugs but if i unplug the temp sensor then when the key is turned on it does send power to the glow plugs for at least a full twenty seconds.

 

[G60ING]