Volkswagen Workshop Service and Repair Manuals

Armature - remove and install Special tools and workshop equipment required

t  Device -VW 463/4-.

t  Torque wrench 2 to 10 Nm -VAG 1783-. Removal: –  Turn off the ignition and all electrical equipment, and remove the key from ignition. –  Disconnect the Battery -A- → Chapter. –  Remove the Starter -B- → Chapter. –  Remove the magnetic switch → Chapter. –  Remove shaft end rear cover, circlip, plain washer, and sealing ring.

–  Remove the fastening screws -arrows- (6 Nm) from the polar case cover cap.

–  Using the Device -VW 463/4- as a guide, slide the brush holder -arrow- and remove it from the armature. –  Remove the armature from the polar case by pulling it.   Note Please be very careful with your fingers, as the armature is strongly pulled by the magnets.

–  Remove the rubber buffer -arrow-. Installation: –  Install the armature in the activation bearing and in the polar case.

–  Fit the armature -arrow- to the activation bearing, together with the operating rod and rubber buffer.   Note Please be very careful with your fingers, as the armature is strongly pulled by the magnets.

–  Fit the brush holder -arrow- using the Device -VW 463/4-, sliding it toward the rotor, and then removing the tool.

–  Place the housing cable seal rubber -1-. –  Install rear cover, paying attention to the correct position of tab and the cover screw holes. –  Fit seal -4-, plain washer -3- and circlip -2- on armature shaft.   Note If you are unable to easily fit the circlip, pull the shaft a little outwards.

–  Install rear axle end cover -1- and tighten the screws with a (2-Nm) torque. –  Install and tighten fastening screws -2- of the polar case cover cap by applying a (6-Nm) torque. –  Install the magnetic switch → Chapter. –  Install the Starter -B- → Chapter.