Volkswagen Touareg 2004-06

Starter

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Removal & Installation



3.2L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the engine from the vehicle.
  4.  
  5. Open the snaps and remove the starter solenoid heat shield mat.
    NOTE
    When removing the nuts from the starter solenoid terminals, always counter-hold the terminal stud in order to avoid damage to the starter solenoid.

  6.  
  7. Pry off the caps from the nuts at the positive (B+) terminal and at terminal 50 on the starter, if present. Remove the nuts.
    NOTE
    When removing the nuts from the starter solenoid terminals, always counterhold the terminal stud in order to avoid damage to starter solenoid.

  8.  
  9. Remove the lower starter bolt on the engine side.
  10.  
  11. Remove the bolt (2) for the cable retainer and set it aside. Remove the nuts (1)
  12.  
  13. Remove the bolt from the exhaust system bracket from the engine side and remove the bracket.
  14.  
  15. Remove the bolt for the coolant pipe on the side of the oil pan.

    Click image to see an enlarged view

    Fig. Remove the lower starter bolt on the engine side-3.2L engines



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    Fig. Remove the bolt (2) for the cable retainer and nuts (1) -3.2L engines



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    Fig. Remove the upper starter bolt-3.2L engines

  16.  
  17. Remove the upper starter bolt on the transmission side.
  18.  
  19. Remove the starter.
  20.  

To install:

  1. Installation is the reverse of removal. Note the following torque specifications:

    Starter mounting bolts: 55 ft. lbs. (75 Nm)
     
    B+ terminal nut: 11 ft. lbs. (15 Nm)
     
    Terminal 50 nut: 71 inch lbs. (8 Nm)
     

  2.  

4.2L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the engine from the vehicle.
  4.  
  5. Remove the exhaust manifold.
  6.  
  7. Remove bolt (1). Unclip cable harness (2) and remove the cable retainer (3) from mounting.
  8.  
  9. Remove the nuts and bolts from the engine mount (arrows).

    Click image to see an enlarged view

    Fig. Remove bolt (1), unclip cable harness (2) and remove the cable retainer (3)-4.2L engines



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    Fig. Remove the nut from the mount-4.2L engines



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    Fig. Remove the bolts securing the mount to the carrier-4.2L engines

  10.  
  11. Lift the engine with a hoist to take the weight off the mount. Remove the engine mount.
  12.  
  13. Remove the three bolts for the engine mount bracket at engine block, then remove the bracket.
  14.  
  15. Pry off the caps from the nuts at the positive (B+) terminal and at terminal 50 on the starter, if present. Remove the nuts.
    NOTE
    When removing the nuts from the starter solenoid terminals, always counterhold the terminal stud in order to avoid damage to starter solenoid.

  16.  
  17. Remove the bolts securing the starter, then remove starter.

    Click image to see an enlarged view

    Fig. Lower starter mounting bolt location-4.2L engines



    Click image to see an enlarged view

    Fig. Upper starter mounting bolt location-4.2L engines

  18.  

To install:

  1. Installation is the reverse of removal. Note the following torque specifications:

    Starter mounting bolts: 55 ft. lbs. (75 Nm)
     
    B+ terminal nut: 11 ft. lbs. (15 Nm)
     
    Terminal 50 nut: 71 inch lbs. (8 Nm)
     
    Engine bracket to mount: 55 ft. lbs. (75 Nm)
     
    Engine mount to carrier: 44 ft. lbs. (60 Nm)
     

  2.  

Testing & Troubleshooting



Voltage Drop Test

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

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

  16.  

 
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