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

Removing and installing starter, 4-cylinder diesel engine with manual 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
Extensions and tool inserts
Removing:
Disconnect battery
Chapter
.
Remove underbody guard.
Unclip sheathing of cable connections
arrows
to starter and pull down.
Release and disconnect connector
1
of terminal 50 on starter.
Unscrew securing nut
2
of terminal 30 from starter.
Unscrew earth connection from starter
arrow
.
Note
When removing and installing, the securing bolts of the starter can be reached without having to remove the diesel particulate filter, if one or more extensions are used.
To obtain access to the upper starter securing bolt, work from gearbox end.
To obtain access to the lower starter securing bolt, work from engine end.
Unscrew securing bolts
arrows
from starter.
To remove starter, unscrew bracket of coolant line from engine at top
arrow
.
Unscrew oil return connection piece
1
and place to one side. Wipe up any escaping engine oil with a cloth. Also unscrew bracket of coolant line
2
and push coolant line upwards.
Release oil return line from turbocharger at bottom. Push oil return line a little away from cylinder block so that starter can be guided out.
Rotate starter
1
a little if required and remove it forwards.
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
.