URS6 No Sparky No Starty

[Jolfa]

Balls.

[newsh]

Ah
Well at least you’ve got a diagnosis!
Apparently you can weld the pin back on through the starter hole, sounds a pain though..
Did you find the broken off piece?

[Jolfa]

Not yet, hoping a bit of magnet fishing will do the trick...

[John.]

Not yet, hoping a bit of magnet fishing will do the trick...

Good luck with that.

[UrS4boy]

After a bit more digging, testing, multimetering and swearing, I have established that the problem is a missing G4 pin on the flywheel and the telltale marks where it used to be, it appears to have whacked the sensor on the way out too

You did good to find that. Many people have pulled all their hair out before they have stumbled onto that. Here is some info for you:

Detailed Location and Size of the G4 Crank Position Pin:

http://forums.quattroworld.com/s4s6/msgs/51259.phtml

With luck and skill it can be welded back onto the flywheel through the starter hole.

[Jolfa]

Good luck with that.

I'm not holding my breath would be good to find it before it shoots it through the bell housing though, there's marks all over the pressure plate where it's rattled around so it's probably not in the best shape even if I do find it

I've printed off all the relevant info from that guide and presented the problem to a mechanic friend (I'd do it myself if my tools/welder weren't all the other side of the world and I had some ramps ), he's going to have a crack at it Wednesday night

[merlin's S4]

BTDT! I had the exact same problem a few years ago. I was lucky enough to find the pin in the bell housing when I removed the starter motor. I had a welder friend Tig weld it back on through the starter hole. It wasn't easy but only took a couple of hours in the end.

Here's my thread from 2012... https://www.s2forum.com/forum/techni...nd-won-t-start

[Jolfa]

Well all back up and running, enormous thanks as usual to you lot

Usual missing piece picture -



but the missing piece remains missing unfortunately so we had to make one based on the dimensions from the other thread



but whilst searching for the missing piece I found the culprit



looks to be a stray sump bolt and a companion oil leak from the area....

4 hours of messing and accidentally welding the wrong spot (messing up the clearances) and all is well in the world.

No pics of the weld as it's not the neatest job, which is why I imagine I couldn't find any pics to compare to but we held it in place with a strong magnet on a stick and got there in the end

[Mikes2]

Somebody has replaced the sump gasket and failed to tighten the bolts next to the flywheel. My S2 was the same when I picked it up as a non runner

[Jolfa]

Are those bolts accessible with the gearbox in situ?

[Mikes2]

yes they are. there are grooves in the flywheel to allow access. you may need to turn the engine by hand to line them up