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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Fig. Close up view of the starter drive gear



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Fig. When the solenoid is energized the starter drive is pushed out and meshes with the flywheel to crank the engine


NOTE
On A1 and A2 platform vehicles equipped with 010 automatic transaxle, access to the starter motor is limited. Although not necessary, it is recommended that the intake and exhaust manifolds be removed to access the starter.

  1. For safety purposes, disconnect the battery ground cable.
  2.  
  3. Raise and safely support the front of the vehicle with jackstands.
  4.  
  5. For A3 vehicles, use a floor jack (with a block of wood on the chock) to 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 starter is being removed. The bolts that secure the starter to the transaxle are also used to secure the front engine mount to the transaxle.
  6.  
  7. If necessary, label the small wires before disconnecting them.
  8.  
  9. Disconnect the large cable, which is the positive battery cable, from the solenoid.
  10.  
  11. On 010 transaxle-equipped vehicles, remove the bracket that secures the starter to the engine.
  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:


NOTE
On vehicles with a manual transaxle, there is a bushing where the starter shaft fits into the bell housing. If the shaft or bushing are worn or if the starter has been jamming, the bushing should be replaced. There is a special bushing removal tool available but a small inside bearing removal tool is usually sufficient.

  1. Install the starter into the transaxle.
  2.  
  3. Tighten the starter mounting bolts as follows:
    1. All vehicles except 010 transaxle:

      M8 nut: 89 inch lbs. (10 Nm)
       
      M10 nut and bolt: 44 ft. lbs. (60 Nm)
       
      M12 bolt: 33 ft. lbs. (45 Nm)
       

    2.  
    3. 010 transaxle only:

      Mounting flange bolt: 15 ft. lbs. (20 Nm)
       
      Mounting bracket bolt: 18 ft. lbs. (25 Nm)
       

    4.  

  4.  
  5. Attach the electrical connections to the starter.
  6.  


NOTE
Be careful not to over tighten the battery cable connection. The metal is soft and the threads will strip easily.

  1. Lower the vehicle from the jackstands.
  2.  
  3. Connect the negative battery cable.
  4.  

SOLENOID OR RELAY REPLACEMENT



  1. Remove the starter from the vehicle.
  2.  
  3. Remove the nut which secures the connector strip on the end of the solenoid.
  4.  
  5. Take out the two retaining screws on the mounting bracket and withdraw the solenoid after it has been unhooked from the operating lever.
  6.  
  7. Installation is the reverse of removal. In order to facilitate engagement of the lever, the pinion should be pulled out as far as possible when inserting the solenoid.
  8.  

 
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