Starting troubles!

[ZAddict32]

Ok NICO, I really wanted to avoid a new post for this because there are so many similar posts but have not been able to find an answer anywhere! I have a tt I've been building for a year now. To jump ahead to whats going on now, I finished the motor, put it in, ran it, took it back out (forgot to put the dipstick tube on :/ .) Put the tube in, put everything back together. Motors back in, everything is completed. Start putting coolant in the radiator and it started pouring out of the back of the block. Ordered 12 freeze plugs, and ready to pull the motor back out, but I want to run the car for a few minutes and check all other systems before I do (had we put coolant in it before, I wouldn't be on my second pull already. The problem is the dang thing wont start. Pulled codes (11 only- CAS). Have checked/tested/replaced EVERYTHING I can think of. Checked all fuses, just in case, checked/swapped out relays (I have a NA parts car) including starter relay, ignition coil relay, battery relay (fuse block by battery). Swapped CAS. Swapped battery just in case with one known to have charge. Locked and unlocked doors with factory sec system and aftermarket. Jumped clutch switch. Replaced starter.
Everytime I start it, with each swapped part all I'm getting is a click from the starter (fuel pump is priming as well). The thing that is stumping me is that it started before!! Had it running for a minute or two. The only difference is that now it has a full exhaust. Checked the motor for hydrolock as well. (Turned motor by hand)
The only other thing worth noting is that the power steering belt has backed off a little bit so its on the lip of the pulley. Is this belt supposed to be super tight even with the tensioner loosened all the way? Wondering if I have the wrong belt? Even so, this should not keep it from starting correct? Wont even turn over without a jumper wire, but wont start with one (sparks were flying) The only thing I can think to check/replace is the ignition switch, but I don't think I would be getting a response at all from the starter if that is the case?

Any and all help appreciated, I don't think I left anything out. Car is manual, PTU is black plastic (from what I've read that is the "new style")

ZAddict32

[t.mcginley.jr]

Ok so when you go to start it (without trying to jump it) you just get clicking from the starter? it doesn't try to turn over?

If so, it sounds like an open ground somewhere or bad/loose/corroded battery terminals. Did you remember to attach the main ground to the one bellhousing bolt? and all the little grounds on top of the plenum?

It definitely sounds like when you put it back in (or maybe while you were pulling it back out) something didn't get hooked back up correctly.

[ZAddict32]

I have 3 grounds off of the plenum and one connected to the trans mount bolt. The one on the bellhousing on the top? I can't remember doing it myself, just wanted to make sure where it was.

[ZAddict32]

Just noticed, there are only two connections off the starter.. (DOH!) I believe one is the sending unit (has a plug connector) and the other is a small black wire that is built in (from the motor to the solenoid) to the starter. I think I'm looking for one that has a square plate fitting that attaches with a nut and bolt. It comes from the power side of the battery correct? Looking frantically as we speak...


EDIT:: Car started! The wire I thought was disconnected was actually connected but by taking the starter off to check it the bendix popped (back in to place). It was too tight!! The top stud was stripped out for the starter and I tried to replace it with a bolt but it bottomed out where I assume the stud broke. Backed it off and mocked it up barely tight she fired right up.

Now, on to the second pull. ( freeze plugs... )