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I don't know exactly what the VW setup is, but if it has a floating plate contactor like the Denso's it may be
an indication that the plate is almost burned out.
If so, one day it just won't start at all. I had that happen to my Cressida (fortunately in the garage at home) just after the warranty ran out.
I fitted a heavier duty plate (cost $5!) and it never happened again. Hardest part was getting the starter out and in again — that model Cressida was built by hanging a starter in mid-air and assembling the car around it.
Might also be a dirty contact somewhere, but anyway either check it or get it checked before it sticks you up.
Yes — as I said, I'm not familiar with how the VW starter does it, but on the Denso's (of which I've repaired quite a few, though not lately as I can't get under the things any more) there's a flat plate that's pushed forward by the solenoid that engages the pinion with the ring gear. You just dismantle the solenoid, drop the remains of old plate out, clean the two contacts, drop a new one in and re-assemble. If the starter's accessible, about 20 minutes work.
How long a plate lasts depends on the number of starts — to make the hard-to-replace contacts last longer it's designed to be a sacrificial item and a bit more metal burns off every time the starter is used.
When you actuate the starter a small current is fed to the motor — just enough to start it rotating slowly, and the solenoid is powered up, which pushes the starter's armature forward and engages the pinion. At the end of the stroke the floating plate is pushed hard against the two contacts and supplies full current to the motor — this is where the arcing occurs.
When the engine fires and the key is released the solenoid shuts off and a spring returns the armature and pinion to the static position, in the process releasing the plate and cutting off motor power — since current flows until contact is broken further arcing usually occurs at this point.
Whilst there are minor differences between brands, basically most starters now work this way.
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