Starter With Manual Transmission, Removing and Installing

Starter - 4-Cylinder Engine With Manual Transmission, 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.

Special tools, testers and auxiliary items needed







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







- VAG 1332 Torque wrench (or equivalent 40 - 200 Nm )

Removing

CAUTION:
- Switch off all electrical consumers.
- Switch ignition off and remove ignition key.







- Where applicable, remove cover -2- near intake manifold.

NOTE: Cover for 132kW (180 bhp) engine is illustrated here. Cover for 165kW (225 bhp) engine is similar.

- Remove battery.







- Remove bolt -arrow-.
- Remove front battery cover -1-.







- Unclip main fuse box from top of battery mount -arrow-.
- Remove bolts -1- and -2- and detach rear battery cover from battery carrier.







- Remove bolts -arrows-.
- Remove battery carrier.







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







- Where applicable, remove bolt -arrow- and move power steering pressure pipe to one side.
- Remove wire guide.







- Remove bolt -1-.
- Remove left front wheel/tire







- Where applicable, remove headlight range control bracket -arrows-.
- Lift vehicle.







- Remove screws -1-, -2- and -3-.
- Remove center noise insulation panel.







- Remove screws -arrows-.
- Remove right noise insulation panel.







- Remove screws -arrows-.
- Remove left noise insulation panel.







- Where applicable, remove power steering pipe from connecting pipe -arrows-.







- Where applicable, remove connecting pipe between charge-air coolers on left and right long members.







- Remove both hoses to charge-air cooler.
- Remove connecting pipe.







- Remove bolt -2-.
- Remove starter.

Installing
Install in reverse order of removal, noting the following:
- Install battery carrier.
- Install battery.
- Perform work steps specified in table

Tightening torques

Starter to transmission - bolt M10 45 Nm
Starter to transmission - bolt M12 65 Nm
Connecting pipe to long member - bolt 20 Nm
Power steering pressure pipe to starter - bolt 22 Nm
Wire guide to starter - bolt 22 Nm
Terminal B+ to solenoid - nut 16 Nm
Battery carrier to long member - bolt 10 Nm