5.0L TDI

Starter

Special tools, testers and auxiliary items required

• Torque Wrench (V.A.G 1331/)

• Torque Wrench (V.A.G 1332/)

• Shop Crane (VAS 6100)

• Lifting Tackle (3033)

• Transportation Plates (T10126)

• Transportation Plates (T10126/1)


When disconnecting and connecting the battery, always perform the work procedure as described in the repair manual. Refer to => [ Battery, Disconnecting and Connecting ] Battery, Disconnecting and Connecting. Not adhering to sequence will result in the deactivation of Main Battery Switch -E74- and subsequent damage to electrical system components.

Removal

- Remove the engine. Refer to => Engine Mechanical,
Fuel Injection and Glow Plug 10 Removal and Installation.

- Remove right turbocharger. Refer to => Engine
Mechanical, Fuel Injection and Glow Plug 21 Removal and Installation.

- Open the snaps - arrows - and remove the starter solenoid heat shield.






- Remove nut - arrow - from engine mount.






- Bolt (T10126) - 1 - with a bolt M8×40 - 2 - to right cylinder head at rear.







When bolting on, transport strap pin must engage into bore of holder attached on engine side.

- Bolt (T10126/1) - 1 - with a bolt M8×40 - 2 - to left cylinder head at front.







When bolting on, transport strap pin must engage into bore of holder attached on engine side.

- Hook the (3033) into the (VAS 6100).

- Hook (T10126) and (T10126/1) onto (3033).

- Lift the engine with the shop crane (VAS 6100).

- Remove 4 bolts M10×95 - arrows - from right engine support and remove engine support.






- Remove bolt for coolant pipe - arrow - at engine block.






- Remove bolt for coolant pipes - arrow - at transmission.






- Pry off cap from nut at positive ( B+ ) terminal - arrow -.






- Remove nut at solenoid positive ( B+ ) terminal - arrow -.






- Remove nut at solenoid Terminal 50 - arrow -.







Screw connections on magnetic switch can twist.

The solenoid switch can be damaged.

When removing and installing nuts at positive terminal and terminal 50, counterhold the threaded connection at the solenoid switch using an open-end wrench.

- Remove bolt for cable retainer - arrow - and set cables aside.






- Remove lower starter bolt M12×165 - arrow - on engine side.






- Remove upper starter bolt M12×165 - arrow - on transmission side.






- Remove starter.

Installation

Install in reverse order of removal. Note the following:

- Tighten the fasteners to the specification shown in => [ Fastener Tightening Specifications, Starter ] [1][2]Specifications.