Help Needed - Strange Starting Noise

[Gman 29]

Hi all.

 

I've recently had a gti6 engine fitted into my 205, and the starter motor is making a funny noise when starting.

 

I was advised that the starter motor is on its way out, so that was changed today but the noise is still there. Furthermore, I'm running a lightened flywheel (one of Rich W's) and upon inspection, the teeth of the flywheel have small scores on them.

 

The noise itself is very hard to describe, but at times it doesn't sound like its fully catching the fly to turn it over.

 

Any ideas what could be wrong, as I'm worried about damaging the flywheel any further

[Paul_13 212 1 Cars]

That was a bit strange when we looked earlier, hopefully it's not the early version but they should of phased out by now.

It brings to mind that a dturbo starter motor was used as it protuded further!? don't know if its true or not.

 

The starter still making the same noise!? Bast@rd!

 

Really odd as Hovis's car doesn't make that same noise. He's got a lightened flywheel...

Edited July 9, 2011 by Paul_13

[Gman 29]

That was a bit strange when we looked earlier, hopefully it's not the early version but they should of phased out by now.

It brings to mind that a dturbo starter motor was used as it protuded further!? don't know if its true or not.

 

The starter still making the same noise!? Bast@rd!

 

Really odd as Hovis's car doesn't make that same noise. He's got a lightened flywheel...

 

I know mate, right bugger that it's still making the noise.

 

I specifically asked Miles if it was one from a new batch and he said yes, so I shouldn't need a diesel starter. The marks on the fly looks like the starter is only catching the top of the teeth on the fly and not fully engaging.

[Anthony 1,003]

Is the dowell present between the starter and gearbox (on the middle bolt) to locate it properly?

[dee205 3]

Have you taken the starter off and tested it to make sure it's popping out fully when the solonoid is engaged. It won't be long wrecking a flywheel of it's catching enough.

[Paul_13 212 1 Cars]

Is the dowell present between the starter and gearbox (on the middle bolt) to locate it properly?

 

Yep, dowell was there when we put the new starter on.

 

Have you taken the starter off and tested it to make sure it's popping out fully when the solonoid is engaged. It won't be long wrecking a flywheel of it's catching enough.

 

Tested it before installation and it was working fine, popping out as it should.

[Gman 29]

Well I've whipped the stater off to take a few pics.

 

The first shows the starter is sitting flush against the box, so no issues there.

 

 

The second is the starter motor itself. It's been tested and found working fine, and was also the same as the one removed. Should therefore be a gti6 one.

 

 

 

With the starter removed, you can see the damage being done to the lightened flywheel. Considering I've only been driving the thing for 1 month, the damage is quite considerable.

 

 

 

The below pics show various shots showing the gearbox is flush with the engine, so one could assume the gearbox is in the correct position.

 

 

 

 

Any ideas would be gratefully received. Whilst I'm on here, a great thank you goes to Paul for all is help on my car! Top bloke!

Edited July 28, 2011 by pug_ham
Number of images & image filesizes, 800 x 600 / 160k max or use thumbnails as above.

[Gman 29]

Does no one have any advice?

[welshpug 1,666]

where exactly is the damage?

[Paul_13 212 1 Cars]

You can it the photo

[dcc 855]

On the teeth of the flywheel you can see the starter isnt engaging correctly.

 

Them flywheels seem a bit soft

[Anthony 1,003]

where exactly is the damage?

Enlarge the pictures and it's much clearer - looks like it's basically chewing the tops off the ring gear

[M@tt 77]

you can see ontop of the ring teeth on the flywheel it looks as though the starter motor teeth have been biting into the top of the teeth rather than between them.

 

can you get a static marker above/near the flywheel ring teeth and then rotate the flywheel and check that the teeth have been attached perfectly concentrically if it hasn't i guess theres a possibility the starter teeth could ride up onto the top of the ring teeth

 

Matt