Removing and installing starter for 2.5 l 5-cyl. TDI engine with diesel particulate filter, automatic gearbox — VW

🧭 Before you start

Fits: VW Touareg I (7L, 2002–2010)

📋 Procedure

1. ⚠ When batteries are disconnected, the procedure described in the workshop manual must be strictly followed . If the sequence is not maintained, the battery isolator may be triggered and the electrical equipment of the vehicle may be damaged. — Disconnect battery .
2. Remove diesel particulate filter 5-cylinder diesel engine26Removing and installing diesel particulate filter; Removing.
3. Detach press studs (arrows) (total of 4) and remove heat shield mat for solenoid switch.
4. Release and disconnect connection (1) and pull off protective cap (2) from securing nut.
5. ⚠ The threaded connections on the solenoid switch could become twisted.The solenoid switch may be damaged.When tightening or loosening connections for positive cable and terminal 50 cable, counterhold threaded connection on solenoid switch using open jaw spanner. — Unscrew securing nut (1) and remove positive lead (2) from solenoid switch.

6. Unscrew securing bolt (1) and remove cable retainer (2).
7. Remove the two securing nuts (arrows) and remove bracket.
8. Unscrew both securing bolts of starter (arrows).
9. Remove starter from vehicle upwards.
10. ⚠ The threaded connections on the solenoid switch could become twisted.The solenoid switch may be damaged.When tightening or loosening connections for positive cable and terminal 50 cable, counterhold threaded connection on solenoid switch using open jaw spanner. — Tighten threaded connections to specified torque .
11. ⚠ When batteries are reconnected, the procedure described in the workshop manual must be strictly followed . If the sequence is not maintained, the battery isolator may be triggered and the electrical equipment of the vehicle may be damaged.Observe notes for battery terminal clamp bolt . — Reconnect battery .

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