Removing and installing starter, 4-cylinder diesel engine with automatic gearbox — VW

Removing and installing starter, 4-cylinder diesel engine with automatic gearbox
Renewing starter on vehicles with Start/Stop system:
Due to the higher requirements on the starter when the Start/Stop system is activated, e.g. in urban traffic/driving, the deep-cycle resistance has been increased and the ring gear reinforced.
When renewing starter, make sure the new one with the correct part designation as shown in
Electronic Parts Catalogue
is used. Components adapted to Start/Stop system are not identified separately and are not or barely different from normal components in their appearance.
Caution
To disconnect and reconnect the battery, the procedure described in the workshop manual should be strictly adhered to
Chapter
.
Caution
When doing any repair work, especially in the engine compartment, pay attention to the following due to the cramped conditions:
Route electrical wiring so that original wiring layout is restored.
Make sure there is adequate clearance from all moving or hot components.
Special tools and workshop equipment required
Torque wrench (5 - 50 Nm)
V.A.G 1331
Torque wrench (40 - 200 Nm)
V.A.G 1332
Socket set
V.A.G 1835/
Extensions and tool inserts
Removing:
Switch off ignition and all electrical loads, and pull out ignition key.
Disconnect battery
Chapter
.
Remove underbody guard.
Remove intake hose for air filter.
Position engine with
support bracket
10-222A
as shown, and take up weight of engine in installation position.
Attach
hook
10-222A/10
in transport eye.
Attach
additional hook
10-222A/2
in transport eye
arrow
.
Attach
shackle
10-222A/12
with
additional hook
10-222A/2
on
adapter
10-222A/16
.
Remove bolts of right engine support on engine block
4-cylinder diesel engine (2.0 l engine, common rail)
Rep. gr.
10
Assembly and gearbox mountings
.
Pull down sheathing of cable connections
1
on solenoid switch.
Release and disconnect connector
2
of terminal 50 on starter.
Unscrew securing nut
1
of terminal 30 from starter.
Unscrew earth connection from starter
1
.
Note
To obtain access to the lower starter securing bolt, work from engine end.
Unscrew lower securing bolt
1
from starter.
If necessary, use an extension to unscrew the bolt through the engine mounting.
Unscrew upper securing bolt
1
from starter using a long extension.
If fitted, detach bracket for
exhaust gas recirculation cooler changeover valve
N345
from engine block.
Only vehicles with bi-turbo engine
Unscrew banjo bolt
2
for oil supply line
1
.
Catch any escaping oil with a cloth.
Continuation for all vehicles
Remove starter by first moving it in
direction of arrow A
to remove it from gearbox housing and then pull it out upwards in
direction of arrow B
.
Installing:
Installation is carried out in the reverse order. When installing observe the following:
Tighten threaded connections to specified torque given in assembly overview
Chapter
.