How to Install Starter Relay for Heatsoak Problems on an Aircooled Volkswagen (VW) Beetle

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Is your air cooled VW difficult to start? You turn the key to start, and you get nothing. Bosch starters use an electromagnetic solenoid for activating the starter mechanism. Like any electromagnet, the electromagnetic force is substantially reduced when they get hot. ALL Bosch starters suffer from this problem. Bosch makes a hard start relay kit that is easy to install. It uses a relay to provide direct power to the starter. You can buy the kit and follow the installation instructions.

Steps

1. 1
   Purchase a Ford starter relay. The part number at Autozone is Duralast F496.

   
   
2. 2
   

   Wiring
   Purchase a minimum of 4 feet of 10 gauge wire and connectors. Prepare wiring and connectors as shown.
3. 3
   Disconnect the battery by removing the wire connected to the negative battery terminal.
   • Don't work around with your starter with the battery connected.
   • Death or serious injury follows when you accidentally short the connections.
4. 4
   

   VW Starter
   Remove the wire from the “s” terminal from the starter (labeled 1 in the photo).
5. 5
   

   Ford Starter Relay
   Connect it to the “s” terminal on the Ford relay (labeled 1 in the photo).
6. 6
   

   Place wire labeled 2 on the "s” terminal from the starter.
   Place wire labeled 2 on the "s” terminal from the starter.
7. 7
   

   Remove the nut and washer holding wire labeled 2 in place.
   Remove the nut and washer holding wire labeled 2 in place. Ensure wire 2 stays in place over the terminal.
8. 8
   

   Place wire number 3 over the terminal and replace the nut and washer.
   Place wire number 3 over the terminal and replace the nut and washer.
9. 9
   The Ford Starter Relay grounds through the mounting bracket. Mount it near the starter. Be sure to clean the surface before mounting so as to make a good ground connection.
10. 10
    Reconnect the battery and start the vehicle. If the vehicle does not start, check all connections.

    
    

Tips

• Some experts claim installing a Ford starter relay or the Bosch hard start relay kit on a 12 volt VW is a waste of time. I have installed the Ford starter relay on every Beetle I have ever owned.

Warnings

• Safety should always be your #1 focus when working on a vehicle.
• Nothing in this world is so important, that you should ever practice unsafe maintenance on your vehicles.
• Always use the proper tools for the job at hand.
• Don't work around with your starter with the battery connected. Death or serious injury follows when you accidentally short the connections.

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