HOW DO YOU REMOVE THE STARTER MOTOR - Golf Volkswagen Cars & Trucks

STARTER REPLACEMENT (ENGINE ELECTRICAL) Document ID# 688149 Starter Replacement

Removal Procedure

Important: This vehicle uses the PG260 F1 starter motor. The starter motor is serviced only as a complete unit.

1. Disconnect the battery ground (negative) cable from the battery. Refer to Battery Negative Cable Disconnection and Connection.
2. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.



3. Remove the starter motor BAT terminal nut and electrical leads.
4. Remove the starter motor S terminal nut and electrical lead.
5. Remove the torque converter cover. Refer to Torque Converter Cover Replacement in Automatic Transaxle - 4T65-E.



6. Remove the starter motor bolts.
7. Remove the starter motor.

Installation Procedure

1. Install the starter motor.
Notice: Refer to Fastener Notice in Cautions and Notices.

2. Install the starter motor bolts.Tighten:
   Tighten the starter motor bolts to 47 [n-m] (35 lb ft).
3. Install the torque converter cover. Refer to Torque Converter Cover Replacement in Automatic Transaxle - 4T65-E.



4. Install the starter motor S terminal electrical lead and nut. Tighten:
   Tighten the starter motor solenoid S terminal nut to 3 [n-m] (27 lb in).
   
5. Install the starter motor BAT terminal electrical leads and nut. Tighten:
   Tighten the starter motor solenoid BAT terminal nut to 10 [n-m] (89 lb in).
   
6. Lower the vehicle.
7. Install the battery ground (negative) cable to the battery. Refer to Battery Negative Cable Disconnection and Connection.

Starter Motor —2.0L SPI Removal
CAUTION: When repairing the starter motor (11002) or performing other underhood work in the vicinity of the starter motor, be aware that the heavy gauge battery input lead at the starter solenoid (11390) is electrically hot at all times. Failure to follow these instructions could result in personal injury.

1. Disconnect the battery ground cable

1. Remove the air cleaner outlet tube (9B659).

1. Remove the top two starter motor bolts.

1. Raise and support the vehicle.

1. NOTE: A protective cap is installed over the B-terminal and must be replaced after servicing the starter motor and solenoid assembly.
   Disconnect the (A) S-terminal wire, and the (B) B-terminal nut and cable from the starter motor.

6. Remove the lower starter motor bolt and remove the starter motor and solenoid assembly.

Chrysler Caravan/Voyager/Town and Country 1996-1999 Starter - REMOVAL & INSTALLATION(see Figures 7, 8, 9, 10 and 11)



Fig. 7: Disengage the solenoid wiring connector, then the battery positive (B+) nut and wire from the starter motor



Fig. 8: Remove the 3 starter motor-to-transaxle bellhousing mounting bolts



Fig. 9: Remove the starter motor from the vehicle



Fig. 10: After removing the starter motor, examine the teeth of the flywheel for excessive wear or damage. Repair if necessary



Fig. 11: If the old starter is going to be re-installed, check the condition of the pinion gear teeth. Replace the starter if the pinion gear shows excessive wear or damage

1. Disconnect the negative battery cable.
2. Raise and safely support the front of the vehicle securely on jackstands.
3. Disengage the solenoid wiring connector from the terminal. This connection may be held in place by a retaining nut, or it could be a push-in connector.
4. Remove the B+ nut and wire from the starter motor terminal.
5. Remove the starter motor-to-transaxle bellhousing mounting bolts.
6. Remove the starter from the vehicle. If equipped, remove the starter motor spacer.
   

To install:

1. If equipped, hold the starter motor spacer in position.
2. Install the starter motor into position on the vehicle.
3. Install the starter motor-to-transaxle bellhousing mounting bolts. Tighten the mounting bolts to 40 ft. lbs. (54 Nm).
4. Engage the solenoid wiring connector onto the starter terminal.
5. Connect the B+ wire and tighten the retaining nut to 90 inch lbs. (10 Nm).
6. Lower the vehicle.
7. Connect the negative battery cable.
8. Verify starter motor operation.

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SOLENOID REPLACEMENT
(see Figures 5, 6 and 7)

Prior to removing the solenoid from the starter motor unit, matchmark the solenoid-to-starter motor housing position, as shown in the accompanying illustration.

1. Remove the starter motor from the vehicle.
2. Detach the solenoid-to-starter motor wire from the solenoid terminal.

Do not disassemble the solenoid; if the solenoid is defective, replace the entire unit with a new one.

1. Remove the two attaching screws, then slide the solenoid out of the starter motor housing flange.
   

Fig. 5: Before removing the starter motor solenoid, matchmark the solenoid-to-starter motor housing relationship



Fig. 6: Disconnect the field coil lead from the solenoid by loosening the retaining nut ...



Fig. 7: ... then remove the two attaching screws and separate the solenoid from the motor housing


To install:

1. Inspect the solenoid plunger joint for wear or other damage. Replace it, if damage is evident.
2. Apply Suzuki Super Grease A (99000-25010) or equivalent, to the solenoid plunger and to the tip of the lever arm (inside the starter motor-to-solenoid housing hole).
3. Insert the solenoid into the starter motor housing, ensuring that the matchmarks made during removal are aligned.
4. Install and tighten the two attaching screws securely.
5. Attach the starter motor-to-solenoid wire to the solenoid terminal.
6. While the starter motor is removed form the vehicle, perform the testing procedure to ensure that the new solenoid functions properly.
7. Install the starter motor.

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Starter - Removal & installing

1. Disconnect the negative battery cable.
2. Raise and safely support the front of the vehicle securely on jackstands.
3. Disengage the solenoid wiring connector from the terminal. This connection may be held in place by a retaining nut, or it could be a push-in connector.
4. Remove the B+ nut and wire from the starter motor terminal.
5. Remove the starter motor-to-transaxle bellhousing mounting bolts.
6. Remove the starter from the vehicle. If equipped, remove the starter motor spacer.

To install:

1. If equipped, hold the starter motor spacer in position.
2. Install the starter motor into position on the vehicle.
3. Install the starter motor-to-transaxle bellhousing mounting bolts. Tighten the mounting bolts to 40 ft. lbs. (54 Nm).
4. Engage the solenoid wiring connector onto the starter terminal.
5. Connect the B+ wire and tighten the retaining nut to 90 inch lbs. (10 Nm).
6. Lower the vehicle.
7. Connect the negative battery cable.
8. Verify starter motor operation.

Disengage the solenoid wiring connector, then the battery positive (B+) nut and wire from the starter motor



Remove the 3 starter motor-to-transaxle bellhousing mounting bolts



Remove the starter motor from the vehicle


The starter relay is located in the Power Distribution Center (PDC) in the engine compartment. Refer to the underside of the PDC cover for starter relay location.

Hope helped with this (remember rated this help) Good luck.

96 probe, 2.0L 4 cylinder. Should be similar to 626 I think.

Starter Motor
Removal


Exploded View of the Starter Motor Mounting Components

1. CAUTION: When servicing the starter motor or performing other underhood work in the vicinity of the starter motor (11002), be aware that the heavy gauge battery input lead at the starter solenoid is "electrically hot" at all times. A protective cap or boot is provided over this terminal (B-terminal) on all carlines and must be replaced after servicing. Be sure to disconnect the battery ground cable before servicing the starter motor.
   Disconnect the battery ground cable (14301).
   

1. Remove the air cleaner (ACL) and the air cleaner to intake manifold tube (9B697). Refer to Section 03-12A for the procedures.
   

1. Remove the two upper starter motor bolts.
   
   
   
   
   

1. Raise and support the vehicle.
   

1. Remove the intake manifold support bolts and the intake manifold support (9J444).
   
   
   
   
   

1. Disconnect the S-terminal wire.
   

1. Remove the B-terminal wire nut and disconnect the B-terminal wire.
   

1. Remove the lower starter motor bolt.
   

1. Remove the starter motor.
   
   

REMOVAL PROCEDURE

IMPORTANT: This vehicle uses the PG260 F1 starter motor. The starter motor is serviced only as a complete unit.

1. Disconnect the battery ground (negative) cable from the battery.
2. Raise and suitably support the vehicle. Refer to Vehicle Lifting.
3. Remove radiator air baffle assembly.
4. Remove the starter motor BAT terminal nut and electrical leads.
5. Remove the starter motor S terminal nut and electrical lead.
6. Remove the torque converter co
7. Remove the starter motor bolts.
8. Remove the starter motor.

INSTALLATION PROCEDURE

1. Install the starter motor.
2. Install the starter motor bolts. Tighten the starter motor bolts to 47 N.m (35 lb ft)
3. Install the torque converter cover.
4. Install the starter motor S terminal electrical lead and nut. Tighten the starter motor solenoid S terminal nut to 3 N.m (27 lb in).
5. Install the starter motor BAT terminal electrical leads and nut. Tighten the starter motor solenoid BAT terminal nut to 10 N.m (89 lb in) .
6. Install radiator air baffle assembly.
7. Lower the vehicle.
8. Install the battery ground (negative) cable to the battery.

Starter

Removal & Installation 1. Disconnect the positive and negative battery cables.
2. Raise and safely support the vehicle.
3. Remove the starter terminal cover.
4. Remove the terminal nut and separate the battery starter cable from the starter motor.
5. Disconnect the solenoid (S) terminal connector, if equipped with a starter mounted solenoid.
ø To disconnect the hard-shell connector from the solenoid (S) terminal, grasp the plastic shell and pull off; do not pull on the wire. Pull straight off to prevent damage to the connector and (S) terminal.
6. Remove the starter motor retaining bolts.
7. Remove the starter motor from the vehicle.
To Install:
8. Place the starter motor in position and install the starter motor retaining bolts. Tighten the bolts to 15-20 ft. lbs. (20-27 Nm).
9. Install the battery starter cable and a terminal nut to the starter motor. Tighten the terminal nuts to 79 inch lbs. (9 Nm).
10. Connect the solenoid (S) terminal connector, if equipped with a starter mounted solenoid.
11. Install the starter solenoid safety cap. If equipped.
12. Lower the vehicle.
13. Connect the positive and negative battery cables.
14. Start the engine several times to check starter motor operation