Question about 1999 Chevrolet Tahoe

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Removing starter heat shield on 2000 Passat 4cyl Turbo

I am replacing the starter in my 2000 Passat 4cyl Turbo.

I checked out a Hayes repair manual from my local library. It has been somewhat helpful, but it is really lacking in some details and all the pictures are for the 6cyl model which is apparently totally different than the 4 cyl turbo model.

Step 6 says "Remove Starter Heat Shield (if equipped)."

I'm stuck. I can't figure out how to remove the starter heat shield. It looks like there is a hose clamp going all the way around the starter which holds the heat shield in place. But the screw for the clamp is totally inaccessible. I had to look at it for 15 minutes before I could even see it.

Would be grateful if anyone had any info about how to get the starter heat shield off.

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  • andrew466 Nov 28, 2008

    It would appear that the hose clamp that holds the heat shield in place was once oriented so that it was accessible, but over time, it rotated into an inaccessible location. Given that it could not be turned, I took a small chisel and carefully cut through the clamp. Worked quite well since the clamp is so tightly tensioned.

    Now I have the heat shield off and 2 bolts removed, but still the starter doesn't budge. Must be a third bolt that I can't find.

    This has really been a challenging little project. I ended up having to remove the right front wheel to be able to access the 2nd bolt on the starter. Without removing the wheel, there was no way I could find to get to that bolt.

  • andrew466 Dec 04, 2008

    Unfortunately, I inadvertently posted this in the wrong space. I tried to get it moved, but the moderators apparently can't.

    I believe that solution #1 posted by shouldibuyit is targeted at a Chevy Tahoe, not a volkwagen passat, which is the vehicle in question in this post. So, it is not applicable. Thanks for the reply though.

  • andrew466 Dec 04, 2008

    Ok, I now have the thing apart and it really doesn't seem so bad in retrospect.

    Here's what I did:

    1. Loosen the lug nuts on the passenger side front tire (it needs to come off later)

    2. Engage the Parking brake

    3. Place blocks behind the rear wheels

    4. Jack the car up and insert jack stands on both left and right sides. Leave jack tensioned as a precaution

    5. Plug in a memory saver into the cigarette lighter

    6. Disconnect the battery

    7. Remove the belt tensioner for the air conditioner compressor

    8. Remove the (4) mounting bolts for the air conditioner compressor. Be ready with blocks to rest it on, you do not want to remove the vaccuum hoses, you are just moving the compressor out of the way to access the starter.

    9. Remove the wires from the solenoid sitting just above the starter.

    10. You should be able to see the first bolt. Remove it.

    11. Remove the passenger front tire.

    12. You should be able to see the 2nd bolt through the wheel well. Remove this bolt.

    13. Remove the mounting bracket that attaches the starter to the engine block. I had to buy a 6mm hex socket to get enough torque on the bolt to get it loose. I tried a long time to get it off with regular allen wrenches, but could not budge it. A socket gives you a lot more turning power. Wish I had all that time back.....:)

    14. The starter should be easy to remove now.

    15. replace with new starter and reverse operation.

    Note: You do not need to remove the heat shield. I was confused by this.

    Note: I also thought that there were 3 large mounting bolts turns out to be only 2 (i'm not counting the 6mm hex bolt on the other end of the starter).

    Note: Was unsure how long the 9v battery would last, so I used black tape to tape up the ends of all the cables I disconnected under the car and hooked the battery up again while I waited 1 day to get a replacement starter.

    Making a memory saver

    You can make a "memory saver" for about $7. You can buy them from Amazon for about $10, but you have to wait for shipping, etc.. I had a more urgent need, so I headed to radio shack for the pieces and made one myself. You will need:

    + 9v battery
    + auto dc plug for lighter - radio shack #270-1509 $3.99
    + Battery replacement strap - radio shack #270-325 $1.99
    + diode- radio shack #276-1103 $0.99

    (Note: If you make one yourself, it is very important that you wire a diode into the circuit to keep the electricity from the car's 12v battery from exploding the little 9v battery)

    I hope someone finds this helpful.

  • andrew466 Dec 04, 2008

    Case closed!!!



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I am not sure if I have the right engine but this may help and give you a better idea of what you are doing.

2-Wheel Drive (2wd) Models (2wd) Models
2.2L Engine

  1. Remove or disconnect the following:
    • Negative battery cable
    • Front exhaust pipe, if necessary for access
    • Starter heat shield, if equipped
    • Brace rod from the front of the engine and the bell housing
    • Drivers side wheel to access the starter motor wires and the starter motor attaching bracket-to-engine bolt through the opening in the wheel well
    • Wires from the starter solenoid
    • Attaching bracket-to-engine mount bolt
    • Starter-to-engine block bolts. When removing the last bolt, be sure to support the starter to keep it from falling and possibly injuring you.
    • Starter and shims (if equipped) from the vehicle
    • Bracket from the starter assembly, if equipped Removing starter heat shield on 2000 Passat 4cyl T - 0900c15280096824.jpgStarter motor and related components—2.2L engine
To install:
  1. Install or connect the following:
    • Bracket to the starter, if removed. Tighten the bracket nuts to 97 inch lbs. (11 Nm).
    • Starter and shims (if equipped) into position in the vehicle and thread one of the retaining bolts to hold it in position.
    • Bracket-to-engine mount bolt (loosely), if equipped
    • Starter mounting bolt, then tighten all mounting fasteners to 32 ft. lbs. (43 Nm)
    • Wiring to the solenoid
    • Brace rod and tighten the retainers
    • Front exhaust pipe and tighten the fasteners, if removed
    • Starter heat shield, if equipped
    • Driver’s side wheel, if removed
    • Negative battery cable

Posted on Nov 28, 2008


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