Replace the Starter Motor on a 1999 VW Beetle TDi
This article explains and shows how a VW Beetle owner can replace a defective starter motor, and save lots of money on professional repairs.
Note: A lifting device is not needed for this repair.
Steps
- Insert a memory keeper device in the cigar lighter so that the programmed settings in the ECM's ROM memory will not be lost. The cigar lighter is located in the passenger compartment.
- Release the hood lever, located in the passenger compartment.
- Pull the hood release cable toward you and raise the engine hood.
- Using a 10mm nut-driver or 1/4-inch 10mm square drive socket and 1/4-inch square drive ratchet, remove three (3) nuts that secures the top engine cover.
- Remove the vacuum hose attached to bracket at back of top engine cover.
- Remove the oil dip stick, top engine cover, and set aside.
- Using a 10mm nut-driver or combination wrench, remove the cable to the negative post of the cranking battery.
- Remove the cable to the positive post of the battery.
- Remove the bolt that secures the battery hold down bracket.
- Remove the cranking battery from the Beetle TDI.
- Remove the bolts securing the battery tray to the vehicle body.
- Remove the battery tray from the Beetle TDI.
- Remove the battery B+ cable to the starter motor.
- Using a creeper on wheels, position the body (driver-side) underneath the vehicle.
- Using a 3/8-inch square drive 18mm socket and a 3/8-inch square drive ratchet, remove two (2) bolts securing the starter to the engine block.
- Tilt the starter motor, with the hands, and remove from top of the engine.
- Bench test the starter motor to confirm that the starter is defective.
- Place the positive (red) cable of a battery booster pack on the B+ terminal of the starter.
- Position one (1) lead of the jumper wire to the low-voltage exciter terminal of the starter.
- Touch the other lead of jumper wire to the B+ terminal of the starter.
- Clean the negative and positive battery posts with a post cleaning brush.
- Clean corrosion deposits on the battery cables (negative and positive) with sandpaper.
- Position the replacement starter motor on the engine block.
- Install the two (2) bolts securing the starter to the engine block.
- Install the positive cable to the starter B+ terminal.
- Install the battery tray and bolts to secure the tray to the vehicle frame.
- Install the cranking battery in the battery tray.
- Install the battery cover.
- Install the top engine cover, dip stick, and vacuum hose.
- Start the Beetle TDI and take it for a test drive.
Tips
- In Step 21, the starter motor is good if the solenoid will lift and energize the starter pinion. It should spin at roughly 150 to 200rpm's.
- Two (2) tests should be made to fully check the condition of the starter motor. The above test is termed a no-load test. It is tested on the bench out of the vehicle. The second test is a load test. The test is made with the starter installed in the vehicle. Both tests require the use of the battery booster pack.
- Before installing battery cables, coat the negative and positive battery posts with Vaseline to prevent corrosion.
- In Step 26, make sure that the starter pinion engages the teeth on the flywheel when installing the starter motor.
Warnings
- Negligence working around the battery can cause "arcing" resulting in internal damage to an electronic component.
- To prevent "arcing", remove the negative cable first followed by the positive cable.
Things You'll Need
- Memory keeper device
- 10mm nut-driver
- 1/4-inch square drive 10mm socket
- 1/4-inch square drive ratchet
- Creeper on wheels
- 3/8-inch square drive 18mm deep socket
- 3/8-inch square drive ratchet
- Battery booster starting pack
- Sandpaper
- Vaseline
- Jumper wire
