Volkswagen Workshop Service and Repair Manuals

Removing and installing starter, 2.0 l, 199/188 kW TSI engine, dual clutch gearbox 02E (DQ250-6A)

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-

t	Ring spanner 16 mm -T10388-

Removing: –  Disconnect battery → Chapter.

–  Remove securing bolts -2-. –  Loosen spring-type clips -1- using spring-type clip pliers -VAS 5024 A- and push spring-type clips on engine cover panel. –  Remove intake hose -3-.

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

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

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

–  Unfasten screw-type clamps -1- and remove charge air cooling hose -2-.

–  Remove nut -3- of coolant pipe -2- from bolt with washer of starter -1-.

–  Loose nut -2- (dot not remove completely) of coolant pipe -1- from bracket on gearbox housing -3-. –  Remove coolant pipe -1- from bracket on gearbox housing -3- and from bolt with washer from starter.

–  Remove wiring harness -1- from cable duct -2-. –  Press coolant line -3- together with wiring harness -1- upwards.

–  Unscrew lower securing bolt -1- off starter.

–  Unscrew cap nut -2-. Remove earth wires -1- and -3- from stud on longitudinal member.

–  Guide starter -2- under battery tray -1- and remove starter in direction of -arrow- upwards out of vehicle. Installing: Install in the reverse order of removal. When doing this, note the following: –  Tighten threaded connections to specified torques → Chapter.   Note Use 16 mm ring spanner -T10388- to tighten lower starter bolts.