Question about 2003 Volkswagen Jetta TDI
Hello - it sounds to me like a total clutch failure - sorry this is late and you have probably got it sorted by now. D
Posted on Jul 18, 2008
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Park your VW Jetta on a level surface, activate the emergency brake and place blocks behind the back tires for safety. 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 intake and exhaust manifolds for easier access to the starter on Jettas with a 010 automatic transaxle, such as the A1 and A2 platform models.
Place a floor jack under the engine, with a block of wood on the chock, for extra support on models such as the A3 platform. Only use this jack for added support, not to raise the vehicle.
Label the starter electrical connections with masking tape and permanent marker to help you remember where the wires connect to the starter later. Disconnect the starter electrical connections, including the positive battery cable.
Detach the bracket that helps to secure the starter to the engine, if necessary.
Check the bushing on a vehicle with a manual transaxle (located where the starter shaft fits into the bell housing). If the bushing shows wear or the starter was jamming, you need to also replace the bushing.
Support the weight of the starter and remove the starter mounting bolts. Place all nuts and bolts in a safe location to prevent loss, such as a baby food jar. Pull the starter straight away from the transaxle and remove it from the vehicle.
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.
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 on Volkswagen of America (see Resources).
Place the starter in the correct position next to the transaxle. Secure the starter in place with the starter mounting bolts. Torque the bolts to 33 foot pounds (45 Nm) on M12 vehicles and 44 foot pounds (66 Nm) on M10 vehicles.
Tighten the mounting bolts differently on Volkswagen Jettas with a 010 transaxle. Torque the mounting flange bolt to 15 foot pounds (20 Nm) and the mounting bracket bolt to 18 foot pounds (25 Nm).
Connect the wires to the starter. The metal on the battery cable is soft and strips easily, so refrain from over tightening the retaining nut.
Lower your Jetta back to the ground. Reconnect the negative battery cable. Turn the key in the ignition to see if your new starter motor functions correctly.
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