Volkswagen Beetle (1998-2011) TDI - Replace Starter Motor

Volkswagen Beetle (1998-2011)
	;
Manufacturer	Volkswagen
Parent company	Volkswagen Group
Production	1998–2011
Assembly	1998 - 1999: Germany; 2000 - 2010: Puebla, Puebla, Mexico
Predecessor	Volkswagen Beetle
Successor	TBC
Class	Small family car
Body style(s)	2-door sedan; 2-door convertible
Layout	front engine, front-wheel drive, all-wheel drive
Platform	Volkswagen Group A4 (PQ34) platform
Engine(s)	petrol engines:; 1.4L I4 16 valve; 1.6L I4; 1.8L I4 Turbocharged; 2.0L I4; 2.3L VR5 20 valve; 2.5L I5 20 valve; 3.2L VR6 32 valve (RSI) ; diesel engines:; 1.9L I4 TDI
Transmission(s)	5-speed manual; 6-speed manual; 4-speed automatic; 6-speed automatic tiptronic
Wheelbase	99 in
Length	163 in
Width	68 in
Height	59.5 in (1998-2000),; 59 in (hatch 2003-present),; 59.1 in (convertible)
Related	Audi A3 Mk1; Audi TT Mk1; SEAT León Mk1; SEAT Toledo Mk2; Škoda Octavia Mk1; Volkswagen Golf Mk4; Volkswagen Jetta/Bora

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This article explains and shows how a VW Beetle owner can replace a defective starter motor, and save lots of money on professional repairs.

[edit] Tools Needed

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

[edit] Supplies Needed

Replacement starter motor

[edit] Instructions

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.

Memory Keeper Device
Release the hood lever, located in the passenger compartment.
Pull the hood release cable toward you and raise the engine hood.
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.

Removing nuts to top engine cover
Remove the vacuum hose attached to bracket at back of top engine cover.
Remove the oil dip stick, top engine cover, and set aside.
Using a 10mm nutdriver or combination wrench, remove the cable to the negative post of the cranking battery.
Remove the cable to the positive post of the battery.
Remove the bolt that secures the battery hold down bracket.
Remove the cranking battery from the Beetle TDI.
Remove the bolts securing the battery tray to the vehicle body.
Remove the battery tray from the Beetle TDI.

Removing Battery Tray
Remove the battery B+ cable to the starter motor.
Using a creeper on wheels, position the body (driver-side) underneath the vehicle.
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.
Tilt the starter motor, with the hands, and remove from top of the engine.

Tilt the starter motor with your hands.
Bench test the starter motor to confirm that the starter is defective.

Bench Testing Starter Motor
Place the positive (red) cable of a battery booster pack on the B+ terminal of the starter.

Connecting Positive Cable of Battery pack to Starter Terminal
Position one (1) lead of the jumper wire to the low-voltage exciter terminal of the starter.
Touch the other lead of jumper wire to the B+ terminal of the starter.
Clean the negative and positive battery posts with a post cleaning brush.
Clean corrosion deposits on the battery cables (negative and positive) with sandpaper.

Cleaning Battery Cables
Position the replacement starter motor on the engine block.
Install the two (2) bolts securing the starter to the engine block.
Install the positive cable to the starter B+ terminal.

Install Cable to Starter Terminal
Install the battery tray and bolts to secure the tray to the vehicle frame.
Install the cranking battery in the battery tray.

Installed Battery in Beetle TDI
Install the battery cover.

Installing Battery Cover
Install the top engine cover, dip stick, and vacuum hose.
Start the Beetle TDI and take it for a test drive.