How to remove starter from a 1990 Audi 80

some go thru the trans bell housing into the starter nose and by all means they will be metric..also some models have a torque bar attatched to the back of it especial;ly diesel engines..

1990 Audi V-8 Quattro 3.6L DOHC

Starter, removing and installing
Disconnect battery NEGATIVE cable
Disconnect wiring from battery to starter and starter to alternator (large terminal)
Disconnect terminal 50 (small wire to ignition/starter switch)
Remove starter mounting screws on engine/transmission
NOTE: Remove upper bolt on starter by guiding 10 mm Allen socket with extension and flex fitting through opening on transmission housing over final drive
Remove starter motor assembly
Reverse procedure to install

from autozone.com

REMOVAL & INSTALLATION
See Figures 5, 6, 7, 8, 9 and 10

1. Disconnect the negative, then the positive battery cables from the battery.
2. For 1990-94 vehicles, remove the battery and battery tray from the engine compartment.
3. For 1990-94 vehicles, detach the speedometer cable connector from the transaxle.
4. For 1995-98 2.0L turbo engines, remove the air hose.
5. For 1995-98 2.4L engines, remove the air cleaner and air intake hose.
6. If equipped with 1.8L engine, remove the bracket on the lower side if the intake manifold.
7. Detach the starter motor electrical connections.

Fig. Fig. 5: Exploded view of the starter motor and related components-1990-94 vehicles, others similar

Fig. Fig. 6: Unfasten the BAT terminal connector from the starter motor

Fig. Fig. 7: Unplug the starter motor electrical connector

1. Unfasten the starter motor mounting bolts, then remove the starter from the vehicle.

Fig. Fig. 8: Unfasten the starter mounting bolts

Fig. Fig. 9: Remove all of the starter mounting bolts ...

Fig. Fig. 10: ... then remove the starter motor from the vehicle
To install:

1. Clean both surfaces of starter motor flange and rear plate. Install the starter motor onto the engine and secure with the retainer bolts. Tighten the retainers to the specifications shown in the accompanying figure.
2. Attach the electrical harness connector(s) to the starter.
3. If removed, install the intake manifold stay and tighten the retainers to 18 ft. lbs. (25 Nm).
4. For 1995-98 2.4L engines, install the air cleaner and air intake hose.
5. For 1995-98 2.0L turbo engines, install the air hose.
6. For 1990-94 vehicles, attach the speedometer cable to the transaxle. Install the battery tray and battery.
7. Connect the positive, then the negative battery cables.

Operate the starter to assure proper operation.

loosen all the bolts on the alternator,swing it inward,toward the block,then fit belt,swing outward,with a lever to tighten belt,before tightening all bolts.(easy,but spanner rash......)

REMOVAL & INSTALLATION


Fig. After the negative battery cable is disconnected, remove the wire terminals from the starter solenoid


Fig. Remove the lower starter mounting bolts...



Fig. ...followed by the upper bolt, then remove the starter from the transaxle housing


Fig. Lower starter bolt locations-1994 2.0L, 2.0L ABA


Fig. Remove the upper starter bolts


Fig. Mark the location and length of each starter bolt


Fig. Remove the starter


Fig. Close up view of the starter drive gear


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

1. Note the radio security code, and then disconnect the battery ground cable.
2. Raise and safely support the front of the vehicle with jackstands.
3. If installed, remove the lower engine shield.

NOTE The engine must be supported on 1990-97 Passat models as the starter mounting bolts also support the engine-to-transmission mounting surface.

1. If necessary, label the small wires before disconnecting them.
2. On 1990-97 Passat models:
   


3. On Audi A4 and 1998-00 Passat models:
1. Release the number 50 electrical connector from the starter.
2. Then remove the nut for the large battery cable and remove the cable.
3. Loosen then remove the clamp that secures the heat shield to the starter.
4. Remove the fasteners securing the bracket at the front of the starter and remove the bracket.


4. Remove the starter mounting bolts, while supporting the weight of the starter.
5. Pull the starter straight out from the transaxle.

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 is 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. Tighten the related starter motor fasteners as follows:
3. Starter support bracket, M5 nut: 35 inch lbs. (4 Nm)
4. Starter support bracket, M8: 16 ft. lbs. (22Nm)
5. Battery cable to solenoid, M8 nut:10 ft. lbs. (13Nm)
6. hydraulic hose support bracket, M8: 84 inch lbs. (10Nm)
7. Starter mounting fasteners, M10: 44 ft. lbs. (60 Nm)
8. Starter mounting fasteners, M12: 48 ft. lbs. (65 Nm)
9. The balance of the installation is in reverse order of removal.

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. Connect the negative battery cable and enter the radio security code.

Open hood.
Disconnect negative (-) batter cable
Locate the starter (under vehicle).
Remove electrical connections. (be sure to remember/take a picture/ make a drawing/ or mark which wires go to what posts)
Remove mounting bolts.
Remove starter, replace with new starter
Install mounting bolts
Install electrical connections

nut on backside of lower bolt. can accessed under vehicle through small square opening in trans. case . bolts are known to freeze in trans. housing. lots of penetrent and working back and forth.

check for voltage at the starter first on the large red wire.check your starter solenoid. bypass it with a screwdriver touch the two large studs or large and one small one. and it should engage

take off the plastic cover on the upper forward corner of the door, you will see three bolt studs with nuts..Remove the nuts, pull the mirror out enough to disconnect the electrical connector.

this is info i pulled but not sure exactly what engine you have...here are a couple though
REMOVAL & INSTALLATION



Fig. After the negative battery cable is disconnected, remove the wire terminals from the starter solenoid



Fig. Remove the lower starter mounting bolts . . .



Fig. . . . followed by the upper bolt, then remove the starter from the transaxle housing



Fig. Lower starter bolt locations-1994 2.0L, 2.0L ABA



Fig. Remove the upper starter bolts



Fig. Mark the location and length of each starter bolt

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

1. Note the radio security code, and then disconnect the battery ground cable.
2. Raise and safely support the front of the vehicle with jackstands.
3. If installed, remove the lower engine shield.

NOTE
The engine must be supported on 1990-97 Passat models as the starter mounting bolts also support the engine-to-transmission mounting surface. If necessary, label the small wires before disconnecting them.

On 1990-97 Passat models:

1. To support the weight of the engine and transaxle, install the engine support Tool Nos. 10-222A and 10-222A/1, or 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. This is necessary because the bolts that secure the starter to the transaxle are also used to secure the front engine mount to the transaxle.
2. Disconnect the large cable, which is the positive battery cable, from the solenoid.
3. If equipped, remove the bracket that secures the starter to the engine. On Audi A4 and 1998-00 Passat models:

Release the number 50 electrical connector from the starter.

1. Then remove the nut for the large battery cable and remove the cable.
2. Loosen then remove the clamp that secures the heat shield to the starter.
3. Remove the fasteners securing the bracket at the front of the starter and remove the bracket.

Remove the starter mounting bolts, while supporting the weight of the starter.

1. Pull the starter straight out from the transaxle. 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 is 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.
Install the starter into the transaxle.

1. Tighten the related starter motor fasteners as follows:
2. Starter support bracket, M5 nut: 35 inch lbs. (4 Nm)
3. Starter support bracket, M8: 16 ft. lbs. (22Nm)
4. Battery cable to solenoid, M8 nut:10 ft. lbs. (13Nm)
5. hydraulic hose support bracket, M8: 84 inch lbs. (10Nm)
6. Starter mounting fasteners, M10: 44 ft. lbs. (60 Nm)
7. Starter mounting fasteners, M12: 48 ft. lbs. (65 Nm)
8. The balance of the installation is in reverse order of removal

Check out these third-party site for more info. Yeah, we're nice like that.
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