Starter - 4-cylinder engine with manual transmission, removing and installing

CAUTION:

Before beginning repairs on the electrical system:

Obtain the anti-theft radio security code.
Switch off all electrical consumers.
Switch ignition off and remove ignition key.
Disconnect negative ( - ) battery terminal.

When disconnecting and reconnecting battery terminals, observe all applicable Notes and torque specifications, as well as instructions on performing OBD program and electrical system function checks as specified in this article. Refer to Battery, disconnecting and reconnecting .

Special tools, testers and auxiliary items needed

Fig 1: Torque Wrench V.A.G 1331

Courtesy of VOLKSWAGEN UNITED STATES, INC.

VAG 1331 Torque wrench (or equivalent 5 - 50 Nm )

Fig 2: Torque Wrench V.A.G. 1332

Courtesy of VOLKSWAGEN UNITED STATES, INC.

VAG 1332 Torque wrench (or equivalent 40 - 200 Nm )

Removing

CAUTION:

Switch off all electrical consumers.
Switch ignition off and remove ignition key.

Fig 3: Removing Engine Cover Panel

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Where applicable, remove cover -2- near intake manifold.

NOTE: Cover for 132kW (180 bhp) engine is illustrated here. Cover for 165kW (225 bhp) engine is similar.

Remove battery. Refer to Battery, removing and installing .

Fig 4: Front Battery Cover And Bolt

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove bolt -arrow-
Remove front battery cover -1-.

Fig 5: Unclipping Main Fuse Box From Top Of Battery Mount And Locating Rear Battery Cover Bolts

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Unclip main fuse box from top of battery mount -arrow-.
Remove bolts -1- and -2- and detach rear battery cover from battery carrier.

Fig 6: Battery Carrier And Bolts

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove bolts -arrows-.
Remove battery carrier.

Fig 7: Electrical Connection, Terminal Connector & Solenoid Terminal Wire

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect electrical connector -1-.
Unclip connector from wire guide.
Remove nut at starter solenoid terminal B+ -3- and remove connector eyelet from terminal.
Disconnect electrical connector -2-.

Remove wiring from wire guide.

Fig 8: Power Steering Pressure Pipe Retaining Bolt

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Where applicable, remove bolt -arrow- and move power steering pressure pipe to one side.
Remove wire guide.

Fig 9: Identifying Starter Bolts

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove bolt -1-.
Remove left front wheel/tire

Fig 10: Unbolting Bracket For Headlight Range Control In Left Wheelhousing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Where applicable, remove headlight range control bracket -arrows-.
Lift vehicle.

Fig 11: Identifying Center Sound Insulation Fasteners

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove screws -1-, -2- and -3-.
Remove center noise insulation panel.

Fig 12: Right Sound Insulation

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove screws -arrows-.
Remove right noise insulation panel.

Fig 13: Left Sound Insulation Panel

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove screws -arrows-.
Remove left noise insulation panel.

Fig 14: Power Steering Lines At Cross-Piece Pipe

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Where applicable, remove power steering pipe from connecting pipe -arrows-.

Fig 15: Identifying Connecting Line Bolts (Left)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Where applicable, remove connecting pipe between charge-air coolers on left and right long members.

Fig 16: Identifying Connecting Line Bolts & Right Charge Air Coolers

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove both hoses to charge-air cooler.
Remove connecting pipe.

Fig 17: Identifying Starter Bolts

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove bolt -2-.
Remove starter.

Installing

Install in reverse order of removal, noting the following:

Install battery carrier.
Install battery. Refer to Battery, removing and installing .
Perform work steps specified in table. Refer to Battery, disconnecting and reconnecting .

Tightening torques

Component	Nm
Starter to transmission - bolt M10	45
Starter to transmission - bolt M12	65
Connecting pipe to long member - bolt	20
Power steering pressure pipe to starter - bolt	22
Wire guide to starter - bolt	22
Terminal B+ to solenoid - nut	16
Battery carrier to long member - bolt	10