Volkswagen Workshop Service and Repair Manuals

Vehicles with 1.9 l TDI engine and manual gearbox

Special tools and workshop equipment required

t	Torque wrench -V.A.G 1331-

t	Torque wrench -V.A.G 1332-

t	Spring-type clip pliers -VAS 5024-

Removing: –  Disconnect battery → Chapter.

–  Pull engine cover upwards -arrows A- and forwards -arrow B-.

–  Disconnect connector -1- and release spring-type clip -2- using spring type clip pliers -VAS 5024-.

–  Pull vacuum hose -arrow- off air filter housing.

–  Remove securing bolt of air filter housing -arrow-.

–  Release locking lugs -arrows- and take off cover.

–  Pull hose -arrow- off air filter housing and remove. –  Pull air filter housing upwards out of brackets and remove.

–  Slide protective cap in direction of -arrow- off solenoid switch.

–  Unscrew positive wire -1- and disconnect connector from terminal 50 -2-.

–  Unscrew earth wire from securing bolt of starter -arrow-.

–  Remove securing bolt of starter -arrow-. –  Remove noise insulation → General body repairs, exterior; Rep. gr.50.

–  Remove securing nut -1- from lower securing bolt of starter. –  Remove wiring retainer -2-.

–  Remove securing bolt of starter -arrow-. –  Remove starter downwards from vehicle. Installing: Install in the reverse order of removal. When doing this, note the following: –  Tighten threaded connections to specified torques → Chapter.