Forums

Topic: Hot Start Relay  (Read 4540 times)

Offline Russ

Hot Start Relay

« on: July 02, 2008, 09:13:22 PM »
I think this is a big help to older VWs, and buses in particular since they are longer.

When you think about how the factory starting system is wired up, current has to travel from the battery up through to the front fuse block, then through the ignition switch and then all the way back to the starter solenoid. Over time, wiring deteriorates, which adds resistance to the lines and on particularly hot days when you've been driving a while, your VW may not start up at all until things cool down again.

When you install the relay, it now only takes a minimal amount of amps to travel from the switch to the relay, which closes and provides current directly from the battery to the starter. The result is much easier starting. I installed one tonight and was amazed at how much better it worked. No more grinding away on the starter, it started up immediately every time.

Bosch makes a relay kit you can pick up for around $20 from various retailers like Bus Depot or Wolfsburg West. Or, you can make your own with a standard automotive relay, some wires, and some connectors.

I mounted mine right beneath the voltage regulator on the right hand side of the engine compartment, against the firewall. The wiring was routed through a grommet to the starter below. Installation was pretty easy. Every bus probably needs this sooner or later.





Offline Bugnut

  • padded cell.
  • Joined: Aug 2005
  • Posts: 2953

Hot Start Relay

« Reply #1 on: July 02, 2008, 10:56:27 PM »
Cool tip,definetly worth doing.

Offline Ret.Bugtech

Hot Start Relay

« Reply #2 on: July 03, 2008, 08:50:06 AM »
This also works great for old 6v Bugs and Type-3. In the 6volt Type-3 twin carbs ,you had to deal with 2 fuel "shut off " valves and 2 electric chokes.  
      Another trick on the Bug was to move the #30 wire from the fuse panel and put it straight on the Ing. switch. Then run the wire back to the panel. This was the factory "fix"  This doesn't make sence but it work for a while. Then came 8 volt batteries.  
      Or you could spend all weekend "making & breaking" and cleaning connections and cussing alot.
      A fellow named Dick Kite who had his own VW shop here way back in the '60s came up with the relay trick long before I ever heard of anybody doing it anywhere else including Cal. He used a Niehoff AL-162 ($1.50) and later the Ford relay. The rest is history. Dick was one of those N.C. mountain boys who was dumb "Like a Fox" and was one hell of a automotive electrical genuis. No formal training either. :shock:

Offline Zen

  • Show Chairman
  • Club Member
  • LaFayette, GA
  • Joined: Dec 2001
  • Posts: 8842
  • Liked: 2 times

Hot Start Relay

« Reply #3 on: July 03, 2008, 02:11:24 PM »
Along those same lines, if you have a 74 or early 75 Super Beetle (and maybe others, but this is the only place I've seen them), a big source of starting problems in the seat belt interlock relay on the back of the fuse box.  This has to the most over-engineered idea VW ever put in one of their air-cooled vehicles.  There were contact switches in the seat cushions and in the seat belt latches.  If there was someone sitting in the seat, the seat belt had to be latched in order for the relay to kick in.  The ignition wire that already goes from the battery to the fuse block to the ignition switch and back to the starter was fed through this relay.  The switches in the cushions have long since bit the dust and the system has to be by-passed.  The way I've seen it done most often was to wrap a piece of wire around the ignition wire in and out terminals on the relay and then plugging it back in the socket.  That works for a while, but it'll make you pull your hair out (I'm living proof!) when the wire gets covered with corrosion a few years later.  I can't tell you how many good switches and starters I changed out before I figured out what was really wrong with Joy's 75 convertible!  :-x

Once I figured out what the problem was, I pulled the relay out, pulled all the wires out of the fuse block that went to the realy, and removed them all the way back to the seats and seat belts.  Then I took the big heavy wire that from the ignition switch and the one going back to the starter, cut about a foot off of each of them, slid a piece of heat-shirnk tubing over one, soidered the ends together and sealed the connection with the heat-shrink.  It shortened the circuit by about two feet and eliminated 2 push-on terminals and two home-made wire wrapped connections.

Again, I don't know what other vehicles may have them, but if you have intermidant problems with the starter not kicking in on 74 or early 75 Super, this could be the source of your problem.

Offline Ret.Bugtech

Hot Start Relay

« Reply #4 on: July 03, 2008, 02:34:56 PM »
Zen ,I know exactly what you are talking about.  Early Rabbits had a problem like this and it turn out to the seat belt connection on the door when you had to hook up your shoulder harness yourselve.   A lot of people were hurt or killed with this door hook up.  The door would fly open in a accident or you would open the door yourselve and a passing car would come zipping by, take your door off and jerk your Butt out of the car belt and all.  Thank God they quit using that kind of belt system.

Offline Smelly_Cat

Hot Start Relay

« Reply #5 on: July 03, 2008, 06:51:08 PM »
Cool idea Bugtech.  Ejection seat.  SC

Offline Russ

Hot Start Relay

« Reply #6 on: July 03, 2008, 07:14:44 PM »
I've also heard early Rabbits didn't even have a lap belt, only shoulder. If you were in a front end collision you would slide down and get decapitated by the steering wheel.

There was an error while liking
Liking...

About Us

Chattanooga's oldest and largest club for air-cooled and water-cooled Volkswagens, since 1998. Join Us

Follow Us

© 1998-2025 Scenic City Volks Folks