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How to Replace the Starter Motor on a 1999 VW Beetle TDi

from wikiHow - The How to Manual That You Can Edit
This article explains and shows how a VW Beetle owner can replace a defective starter motor, and save lots of money on professional repairs. Note: A lifting device is not needed for this repair.

Steps

1. Insert a memory keeper device in the cigar lighter so that the programmed settings in the ECM's ROM memory will not be lost. The cigar lighter is located in the passenger compartment.
2. Release the hood lever, located in the passenger compartment.
3. Pull the hood release cable toward you and raise the engine hood.
4. Using a 10mm nutdriver or 1/4-inch 10mm square drive socket and 1/4-inch square drive ratchet, remove three (3) nuts that secures the top engine cover.
5. Remove the vacuum hose attached to bracket at back of top engine cover.
6. Remove the oil dip stick, top engine cover, and set aside.
7. Using a 10mm nutdriver or combination wrench, remove the cable to the negative post of the cranking battery.
8. Remove the cable to the positive post of the battery.
9. Remove the bolt that secures the battery hold down bracket.
10. Remove the cranking battery from the Beetle TDI.
11. Remove the bolts securing the battery tray to the vehicle body.
12. Remove the battery tray from the Beetle TDI.
13. Remove the battery B+ cable to the starter motor.
14. Using a creeper on wheels, position the body (driver-side) underneath the vehicle.
15. Using a 3/8-inch square drive 18mm socket and a 3/8-inch square drive ratchet, remove two (2) bolts securing the starter to the engine block.
16. Tilt the starter motor, with the hands, and remove from top of the engine.
17. Bench test the starter motor to confirm that the starter is defective.
18. Place the positive (red) cable of a battery booster pack on the B+ terminal of the starter.
19. Position one (1) lead of the jumper wire to the low-voltage exciter terminal of the starter.
20. Touch the other lead of jumper wire to the B+ terminal of the starter.
21. Clean the negative and positive battery posts with a post cleaning brush.
22. Clean corrosion deposits on the battery cables (negative and positive) with sandpaper.
23. Position the replacement starter motor on the engine block.
24. Install the two (2) bolts securing the starter to the engine block.
25. Install the positive cable to the starter B+ terminal.
26. Install the battery tray and bolts to secure the tray to the vehicle frame.
27. Install the cranking battery in the battery tray.
28. Install the battery cover.
29. Install the top engine cover, dip stick, and vacuum hose.
30. Start the Beetle TDI and take it for a test drive.

Tips

• In Step 21, the starter motor is good if the solenoid will lift and energize the starter pinion. It should spin at roughly 150 to 200rpm's.
• Two (2) tests should be made to fully check the conditon of the starter motor. The above test is termed a no-load test. It is tested on the bench out of the vehicle. The second test is a load test. The test is made with the starter installed in the vehicle. Both tests require the use of the battery booster pack.
• Before installing battery cables, coat the negative and positive battery posts with Vaseline to prevent corrosion.
• In Step 26, make sure that the starter pinion engages the teeth on the flywheel when installing the starter motor.

Warnings

• Negligence working around the battery can cause "arcing" resulting in internal damage to an electronic component.
• To prevent "arcing", remove the negative cable first followed by the positive cable.

Things You'll Need

• Memory keeper device
• 10mm nutdriver
• 1/4-inch square drive 10mm socket
• 1/4-inch square drive ratchet
• Creeper on wheels
• 3/8-inch square drive 18mm deep socket
• 3/8-inch square drive ratchet
• Battery booster starting pack
• Sandpaper
• Vaseline
• Jumper wire

Sources and Citations

• http://www.vwtdirepair.com Darell's VW TDI Maintenance Page

Article provided by wikiHow, a wiki how-to manual. Please edit this article and find author credits at the original wikiHow article on How to Replace the Starter Motor on a 1999 VW Beetle TDi. All content on wikiHow can be shared under a Creative Commons license.