In my Syncros, when they had the stock engine, 18 mpg was about what I typically got wit the AC going. 1-2 mpg is about what you should lose when the AC is running. So this sounds fine. Heat definitely has an effect on the starter, and it doesn't get particularly good cooling located where it is (worse on a Syncro, since the gas tank occupies the headroom right over the starter.) Check the engine/transmission ground straps as well as the battery ground strap.

On Aug 29, 2011, at 12:18 AM, Karl Wolz wrote:

> Went for a shakedown cruise today, wandering up from Phoenix to the top of
> Mingus Mtn. (above 7000 ft.), where we did some scrubbing and checking of
> this and that in nice cool air.  Got back to Phx around 4pm, with the
> temperature around 112 degrees.  Filled up at Costco to check trip mileage
> (17.8, which kinda sucks), turned the key and had super slow starter motor
> for a couple seconds, then normal and fired right up.
>
> Several questions:
> This trip is the first time I've used the AC in about 15 years, and the
> frist time I've used with the 2.1L engine; how much should I expect the A/C
> cut into fuel economy?  I drove about normal speed (65 - 75) for most of the
> trip; this usually yields just shy of 20 mpg.
>
> Starter issue - I've replaced the battery to starter wire and the the
> alternator to starter wire with 2ga.  The starter was recently rebuilt, the
> engine normally turns easily.  I have NOT replaced the starter ground
> connection, and have not inspected that wire.  This slow starter (Uerh -
> uerh) was the reason I replaced the wiring, and since then, it has turned
> quite quickly and starter right up every time.  I'd imagine the heat had
> some effect, and I certainly should take a close look at that battery ground
> wire.  Any other thoughts?
>
> Thanks in advance,
>
> Karl Wolz