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

Removing and installing starter, 4-cylinder TFSI petrol 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
Removing:
Switch off ignition and all electrical loads, and pull out ignition key.
Disconnect battery
Chapter
.
Remove underbody guard.
Removing catalytic converter
Rep. gr.
26
.
Unscrew securing bolts
arrows
on heat shield above starter, and remove heat shield.
Unscrew earth cable connection
arrow
on starter.
Detach guide tube for wires from starter by unscrewing gearbox securing bolt
arrow
.
Unclip wiring connections on plastic bracket on top of gearbox.
Release and disconnect connector
arrow
of terminal 50 on starter.
Unscrew terminal 30 securing nut
arrow
on starter.
Unscrew earth connection from starter
arrow
.
Note
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 upper securing bolt
arrow
from starter.
Unscrew lower securing bolt
arrow
from starter.
Guide out starter in direction of
arrow
between engine support and gear casing (gearbox).
Installing:
Installation is carried out in the reverse order. When installing observe the following:
When connecting terminal 30 on starter, it is essential that connection terminal 30
2
is turned on mounting pin in direction of arrow until it comes into contact with plastic stop
1
on starter. Tighten nut in this position.
DANGER!
If this is not done, the terminal 30 connection of the starter may come into contact with the turbocharger housing, which in turn would cause a short circuit between the starter motor and the battery.
Tighten threaded connections to specified torque given in assembly overview
Chapter
.