Starter - 6-cylinder engine, 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

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

Removing

Disconnect battery. Refer to Battery, disconnecting and reconnecting .

WARNING:

The cooling system is under pressure when the engine is warm. If necessary reduce pressure before repair.
Cover cap of expansion tank with rag and open carefully, as hot steam i.e. hot coolant may escape when opening.

Slowly remove cap from coolant expansion tank.

When removing engine compartment trim cover clips, note the following:

Fig 2: Identifying Fasteners At Lock Carrier & Pin

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To remove clips -1- at lock carrier, press pin -2- approx. 4 mm only (do not press right through). Then remove clip.

Fig 3: Removing Left-Hand Cover Panels On Lock Carrier And Battery

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Remove clips -arrows- from left lock carrier cover -1- and fuse box cover - 2-.

Fig 4: MAF Sensor G70, Guide Hose At Throttle Valve Control Module And Bolts

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Loosen clamp -2- and remove air hose from throttle housing.
Disconnect electrical connector -3- at Mass Airflow Meter (MAF)
Remove bolts -1- and -4-.
Set aside wiring harness -arrow-.

Remove air cleaner housing with MAF and air hose.

Fig 5: Folding Up Fuse Box Bracket

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Unclip protective cover -1- for wiring.
Lift fuse box carrier lid -arrows-.

Fig 6: Removing Fuse Box By Releasing Tabs

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Depress retainers with screwdriver -arrow- and remove fuse box from carrier.

Fig 7: Removing Carrier

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Remove bolts -arrows-.
Remove fuse box carrier.

Fig 8: Disconnect Electrical Connectors, Ground Cable & Unscrewing Wire At Solenoid Switch For Starter

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Disconnect electrical connectors -3- and -4-.
Remove nut at starter solenoid terminal B+ -2- and remove connector eyelet from terminal.
Remove connector -1- from wire guide.
Unclip guide from wires.

Remove wire guide.

CAUTION:

DO NOT loosen or remove Ground (GND) connection -5-.

Remove nut at power steering pressure pipe bracket.
Swivel bracket upwards.

Fig 9: Starter Nut And Bolt

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Remove nut -2- and remove ground connector eyelet from combi-bolt.
Remove bolt -1-.
Remove upper bolt.
Remove starter upwards.

Installing

Install in reverse order of removal, noting the following:

NOTE: If difficulty is encountered when installing the starter Ground (GND) cable and nut, lift vehicle and remove center noise insulation panel for better access.

Install fuse box carrier and lock carrier trim.
Reconnect battery. Refer to Battery, disconnecting and reconnecting .
Perform work steps specified in table. Refer to Battery, disconnecting and reconnecting .

Tightening torques

Component	Nm
Starter to transmission - bolt	40
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