How to Replace the Starter in a VW Passat
Imagine running late to get out the door for work, sitting in your 1990 to 1997 Volkswagen Passat and turning the ignition, but nothing happens. You try the ignition again. Still, nothing happens. Your car won't start. While any number of things can be wrong, such as a dead battery or bad alternator, there's a possibility that you need to replace the starter.
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Things You'll Need
- Battery terminal puller
- Car jack
- Support tools
- Floor jack
- Wrench
- Baby food jar
- Inside bearing removal
- Torque wrench
Instructions
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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.
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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.
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Disconnect the positive battery cable from the solenoid. Also disconnect the remaining electrical connections from the starter.
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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.
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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.
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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.
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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).
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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.
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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.
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Tips & Warnings
Always inspect the battery, solenoid and alternator to be certain they are working properly before replacing a starter. When an engine fails to start, many do-it-yourselfers misdiagnose the problem as the starter and replace it unnecessarily, only to find that the vehicle still won't start.
If you believe your starter is in the problem, use a bench test to see if the starter motor spins and how well the starter is performing. A bench test will check the amp load, voltage and RPMs. If the starter is good, it will draw 60 to 150 amps with no load and up to 250 amps under load.
If your Passat is an older model and/or has high mileage, you should also replace the solenoid.
The disconnection of the negative battery cable may interfere with the on board computer function. Upon reconnection, the computer may need to go through a relearning process.
Never operate the starter for more than 30 seconds at a time. Allow the starter motor to cool for at least two minutes in between starting attempts to prevent permanent damage.
The starter replacement process is different for newer VW Passat models. Consult your owner's manual or a mechanic for details.
