Every third or fourth time I go to start the Karmann Ghia the starter motor spins but the pinion gear does not engage in the flywheel. The car may have the original Bosch starter, but regardless, the current starter motor looks like it has been there for a while. I decided a new starter motor would be a good investment.
When I got ready to install the a new starter motor, I noticed the car already had a “hard start” relay (these are also called hot start relays) in place. As cars age, the wiring ends up losing the ability to carry the necessary juice…and when this is the wire from the ignition switch to the starter motor, you often just a clicking noise without the started engaging. With a “hard start” the weakened current from the ignition switch is able to trip the relay connection and open the circuit from the battery to the starter motor. I was not crazy about where the relay was mounted and based on the condition of the wiring, it looks as if the relay had been in place for some time. Along with the new starter motor, I decided on replacing the hard start relay and associated wiring.
I was able to source a new Bosch starter with the original design that includes the shaft that rests in a bushing in the engine case (the new style Bosch starters no longer have that shaft). Unfortunately, the new Bosch starter did not have the structure that allows for the use of the “D” bolt. Not being able to use the “D” bolt makes installation a bit more difficult…since that bolt is one of the four that hold the engine to the transmission.
With the new hard start relay in place, I was able to bolt up the starter motor and connect the wiring. Since that time, the starter has worked flawlessly.
