Question about 1996 Volkswagen Passat

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How to replace the starter on a 1996 volkswagen passat?

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  • aebrown9184 May 26, 2010

    how to replace a starter on a 1996 volkswagen passat

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  • Master
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Hi,

The Steps are :-

Step 1 Park your VW Passat on a level surface, activate the emergency brake and place blocks behind the back tires for safety. Take note of the radio security code for your vehicle. Disconnect the negative battery cable with a terminal puller. Raise the front end of the car with a jack for easier access to the starter. Remove the lower engine shield, if equipped.
Step 2 Brace the engine because the starter bolts also secure the engine to the transmission mounting surface. Use support tools number 10-222A and 10-222A/1. Another option is to use a floor jack with a wood block on the chock.
Step 3 Disconnect the positive battery cable from the solenoid. Also disconnect the remaining electrical connections from the starter.
Step 4 Support the weight of the starter. Remove the starter mounting bracket and bolts. Place all nuts and bolts in the jar to prevent loss. Pull the starter straight out from the transaxle and remove from the engine.
Step 5 Replace the bushing also if it shows wear or causes the starter to jam. Find the bushing on vehicles with a manual transaxle, where the starter shaft fits into the bell housing. Using a small inside bearing removal tool to remove the bushing.
Step 6 Take your malfunctioning starter to the parts store with you. Aftermarket distributors remanufacture most of the starters they sell, so you can likely obtain a partial credit toward your new starter by exchanging your old one. Be sure that you take care not to damage the starter in transit, because the better condition it is in, the more you can get for it.
Step 7 Purchase a replacement starter that has the same or higher cranking capacity (power rating) as the original starter. Also, match the bolt patterns, drive gears and electrical connections. Your owner's manual may list specifications or the auto parts technician will help you determine them. Purchase an owner's manual from Volkswagen of America (see Resources).
Step 8 Install the new starter by reversing the removal process. Torque the mounting bolts to between 44 and 48 foot pounds (60 to 65 Nm). Torque the support bracket bolt to 16 foot pounds (22 Nm). Tighten the battery cable just enough that it's secure in order to avoid stripping the wire.
Step 9 Lower your Passat back to the ground. Reconnect the negative battery cable. Turn the key in the ignition to see if your new starter motor functions correctly.

Let me know,if needed further assistance.

Hope i helped you.

Thanks for using ' Fixya ' and have a nice day!!

Posted on May 26, 2010

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  • Master
  • 1,297 Answers

Disconnect negative battery cable.
Support engine/transmission assembly with Support Beam (VW 10-222A ) and Leg Set (VW 10-222A/1 ).
how to replace the starter - 994b6ff.gif

Remove Black plastic cap and connector from solenoid.
Disconnect connector from spade terminal on solenoid. Remove nuts and wiring from solenoid. Remove M8 nut from stud. On 2.0L engine, remove M12 x 60 bolt securing starter to front console. On all models, remove M10 nuts securing starter.

To install, reverse removal procedure. Tighten starter mounting bolt/nuts to specification.
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Posted on May 26, 2010

  • Sean Reisdorf
    Sean Reisdorf May 26, 2010

    how else can I assist you in your quest to replace the starter in order to raise my "thumbs-up" rating from 2 to 4?

    Maybe I forgot something else you needed/wanted?


    Sean



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You should never connect a 12volt to the compressor solenoid.unless you unplug it first, because on some cars the ac solenoid is driven by an electronic circuit. Semiconductors are very sensitive to excessive current. I once had to repair the computer on a mercedes because the other mechanic did that. Luckily I know how to repair electronic circuits, or they would have bought a 500 dollars computer the little chip that blew only costed a dollar fifty cents at radio shack,.LOL. Anyways back to your problem, Have you checked if there is a leak, and all the refrigerant might have leaked out? This would prevent the compressor from coming on. Along the ac line there is a switch, sometimes by the reciever drier, when the system looses refrigerant the pressure inside drops and that pressure switch disable the compressor. , and the compressor wont come on. This is to protect the compressor, because it will be damaged if you run it without refrigerant. Ac clutch solenoid is usually is not driven by relay, because an ac solenoid don't really take much current to to kick in, unless of course it is shorted. It would either be directly from the inside switch usually in series with the fan control or driven by a small transistor in a circuit, and the electronic circuit is driven by the ac controls inside. I think the problem with your ac is that it has no refrigerant thats why the compressor wont come on.

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http://ezinearticles.com/?Find-the-Free-Auto-Repair-Manual-You-Need-Online&id=92717

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SOURCE: where is the thermastat located on a 1996

That engine is an ALH engine code and 1.9l TDI non pump deuse...The thermostat for engine cooling is located within a Thermostat Housing. Follow the bottom radiator hose leading to engine block, where it meets teh block you will see the housing. It looks like this http://www.drivewire.com/search/?Ntt=Thermostat+housing&N=0&uts=true&t_event=true

Be sure and be careful, it is a plastic assembly and can crack when removing or reinstalling. There are torque specifications for it as well that must be observed. The torque settings are located on this pdf. They are under Thermostat Housing. http://pics.tdiclub.com/data/500/PopularTorqueSettings.pdf

You CANNOT put just any antifreeze/coolant into a VW TDI no matter what someone tells you. Even if the bottle says UNIVERSAL. If you are doing this repair and doing it right then you need PENTOSIN antifreeze/coolant that meets AVG (American Volkswagen Group) specs. Look at www.tdiclub.com for some great tips on upkeep of your car, ask questions, etc. Most of the time you can find a local TDI expert who will help free of charge just to tinker. These TDI engines are big hobby engines! Some guys have Million Milers! They also usually have extra fluids, parts, etc sitting around from helping other people!

Posted on Jun 05, 2010

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