Volkswagen Golf/Jetta/Cabriole 1990-1999

Starter

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TESTING



Voltage Drop Test

NOTE
The battery must be in good condition and fully charged prior to performing this test.

  1. Disable the ignition system by unplugging the coil pack. Verify that the vehicle will not start.
  2.  
  3. Connect a voltmeter between the positive terminal of the battery and the starter B+ circuit.
  4.  
  5. Turn the ignition key to the START position and note the voltage on the meter.
  6.  
  7. If voltage reads 0.5 volts or more, there is high resistance in the starter cables or the cable ground, repair as necessary. If the voltage reading is ok proceed to the next step.
  8.  
  9. Connect a voltmeter between the positive terminal of the battery and the starter M circuit.
  10.  
  11. Turn the ignition key to the START position and note the voltage on the meter.
  12.  
  13. If voltage reads 0.5 volts or more, there is high resistance in the starter. Repair or replace the starter as necessary.
  14.  


NOTE
Many automotive parts stores have starter bench testers available for use by customers. A starter bench test is the most definitive way to determine the condition of your starter.

REMOVAL & INSTALLATION



Fox
Non-Air conditioned models
  1. Disconnect the negative battery cable for safety purposes.
  2.  
  3. Raise and safely support the front of the vehicle with jackstands.
  4.  
  5. If necessary, label the small wires before disconnecting them.
  6.  
  7. Disconnect the large cable, which is the positive battery cable, from the solenoid.
  8.  
  9. Remove the starter mounting bolts, while supporting the weight of the starter.
  10.  
  11. Pull the starter straight out from the transaxle.
  12.  

To install:

  1. Inspect the starter bushing in the transaxle, and replace it if necessary.
  2.  
  3. Lightly lubricate the starter bushing with grease.
  4.  
  5. Place the starter into the transaxle, and tighten the starter mounting bolts to 18 ft. lbs. (25 Nm).
  6.  
  7. Reconnect the wiring to the starter. Do not overtighten the positive battery terminal nut on the starter solenoid.
  8.  
  9. Remove the jackstands, and lower the vehicle.
  10.  
  11. Connect the negative battery cable.
  12.  

Air conditioned models

NOTE
On Foxes with air conditioning, it is necessary to remove the passenger side engine mount to allow enough clearance for the starter to be removed from the transaxle.

  1. Disconnect the negative battery cable for safety purposes.
  2.  
  3. Raise and safely support the front of the vehicle with jackstands.
  4.  
  5. Using a floor jack, (with a block of wood on the chock) support the engine by the oil pan. Do NOT jack the car by the oil pan under any circumstances! The floor jack is ONLY to support the engine while the passenger side engine mount is being removed.
  6.  
  7. Remove the passenger side engine mount by unbolting it from the engine block and the subframe.
  8.  
  9. If necessary, label the small wires before disconnecting them.
  10.  
  11. Disconnect the large cable, which is the positive battery cable, from the solenoid.
  12.  
  13. Remove the starter mounting bolts, while supporting the weight of the starter.
  14.  
  15. Pull the starter straight out from the transaxle.
  16.  

To install:

  1. Inspect the starter bushing in the transaxle, and replace it if necessary.
  2.  
  3. Lightly lubricate the starter bushing with grease.
  4.  
  5. Place the starter into the transaxle, and tighten the starter mounting bolts to 18 ft. lbs. (25 Nm).
  6.  
  7. Reconnect the wiring to the starter. Do not overtighten the positive battery terminal nut on the starter solenoid.
  8.  
  9. Install the engine mount. Tighten the bracket-to-engine bolts to 26 ft. lbs. (35 Nm) and the engine mount-to-subframe nut to 30 ft. lbs. (40 Nm).
  10.  
  11. Remove the floor jack from the oil pan, and place it on the subframe. Raise the vehicle slightly to remove the jackstands, and lower the vehicle.
  12.  
  13. Connect the negative battery cable.
  14.  

All others


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Fig. After the negative battery cable is disconnected, remove the wire terminals from the starter solenoid



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Fig. Remove the lower starter mounting bolts . . .



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Fig. . . . followed by the upper bolt, then remove the starter from the transaxle housing



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Fig. Lower starter bolt locations-1994 2.0L, 8 valve



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Fig. Remove the upper starter bolts



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Fig. Mark the location and length of each starter bolt



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Fig. Remove the starter



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