Removal and installation the starter (VW Passat B4)

To remove, disconnect the wire from the negative terminal of the battery. Suspend the power unit with hoists and unscrew the starter mounting bolts, which also serve to secure the front engine mount bracket. Cut the two plastic clamps securing the starter wires to the traction relay. Disconnect the two wire connectors from the traction relay, unscrew the mounting nut and disconnect the wires coming from the battery and generator. Unscrew the two bolts securing the starter to the clutch housing and remove the starter. Check the condition of the flywheel ring gear teeth.

For installation, if replacement of the starter front cover bushing located in the clutch housing is required, press it out using a small inertial puller with internal grips. Place the new bushing in oil for 20 minutes, then press it into place using a mandrel of the required size. Install the starter, screw in and tighten the mounting bolts. Connect the plug connectors, wires from the battery and generator. Secure the wires to the traction relay with two new plastic clamps. Disconnect the hoist slings from the power unit. Connect the wire to the negative terminal of the battery.