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1995-96 STARTING & CHARGING SYSTEMS Volkswagen Starters Cabrio, Golf III, GTI, Jetta III DESCRIPTION Starter is a brush type, series-wound electric motor with an overrunning clutch. Field frame is enclosed by commutator end frame and drive bushing, and carries pole shoes and field coils. A splined armature shaft drive end carries drive assembly. TROUBLE SHOOTING NOTE: ON-VEHICLE TESTING STARTER DOES NOT CRANK ENGINE 1) Ensure battery is fully charged. Ensure electrical and ground connections are clean and tight. With ignition switch in START position, measure voltage at spade terminal of starter solenoid. Reading should be at least 8 volts. If voltage is as specified, go to step 3). If voltage is not as specified, go to next step. 2) Measure voltage at ignition switch. If reading is at least 8 volts, check wiring between ignition switch and starter solenoid. If voltage is not as specified, replace ignition switch. 3) While operating starter, measure voltage at field (starter) terminal of starter solenoid. If reading is at least 8 volts, repair or replace starter. If reading is less than 8 volts, replace starter solenoid. NOTE: See TROUBLE SHOOTING article in GENERAL INFORMATION. On vehicles with automatic transmission, also check park/neutral switch. STARTER CRANKS TOO SLOWLY TO START ENGINE Ensure battery is fully charged. Ensure electrical and ground connections are clean and tight. If necessary, clean and tighten ground strap between transmission and body. DO NOT loosen ground strap on body. If starter still turns slowly, repair or replace starter. REMOVAL & INSTALLATION Removal & Installation 1) Disconnect negative battery cable. Support engine/transmission assembly with Support Beam (VW 10-222A) and Leg

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Starter Motor Removal WARNING: WHEN PERFORMING MAINTENANCE ON THE STARTING SYSTEM BE AWARE THAT HEAVY GAUGE LEADS ARE CONNECTED DIRECTLY TO THE BATTERY. MAKE SURE PROTECTIVE CAPS ARE IN PLACE WHEN MAINTENANCE IS COMPLETE. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 1. Disconnect the battery ground cable. 2. Raise and support the vehicle; refer to Section 100-02 . 3. Remove the starter motor solenoid terminal cover (11N087). 4. NOTE: The 4.6L engine is shown; the 5.4L engine is similar. Disconnect the starter motor electrical connections. 1. Remove the nuts. 2. Remove the battery cable. 3. Remove the starter solenoid wire. 5. NOTE: The 4.6L engine is shown; the 5.4L engine is similar. Remove the (A) starter motor ground cable nut and the (B) starter motor ground cable. 6. Remove the starter. 1. Remove the two bolts. 2. Remove the starter. Installation WARNING: WHEN PERFORMING MAINTENANCE ON THE STARTING SYSTEM BE AWARE THAT HEAVY GAUGE LEADS ARE CONNECTED DIRECTLY TO THE BATTERY. MAKE SURE PROTECTIVE CAPS ARE IN PLACE WHEN MAINTENANCE IS COMPLETE. 1. Install the starter motor. 1. Position the starter motor. 2. Install the two bolts. 2. NOTE: The 4.6L engine is shown; the 5.4L engine is similar. Connect the (A) starter motor ground cable and install the (B) starter motor ground cable nut. 3. NOTE: The 4.6L engine is shown; the 5.4L engine is similar. Connect the starter motor electrical connections. 1. Position the starter solenoid wire. 2. Position the battery cable. 3. Install the two nuts. 4. Install the starter motor solenoid terminal cover. 5. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Lower the vehicle. 6. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Connect the battery ground cable.

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The fuse box is located under dashboard on driver’s side. Underhood fuse panel is located in engine compartment beside battery. Cars equipped with anti-lock brake system have a third fuse box for ABS in front of the engine compartment on passenger’s side. FUSE PANEL IDENTIFICATION (1988-91) Fuse & Circuit Breaker Identification 1 – 10 Amp Integrated Control Unit, Combination Switch, Gauge Assembly, Back-Up Lights Switch, Shift Position Console Switch, Clock (1990), Shift Lock Solenoid (1990), Interlock Control Unit (1990), Automatic Seat Belts (If Equipped) 2 – 10 Amp Starter Solenoid, PGM-FI Main Relay, PGM-FI Electronic Control Unit, Integrated Control Unit 3 – 20 Amp Power Door Locks (If Equipped) 4 – 10 Amp Right Headlight High Beam, High Beam Indicator Light, Daytime Running Lights Relay (Canada) 5 – 10 Amp Left Headlight High Beam 6 – 30 Amp Sun Roof Motor (If Equipped) 7 – 10 Amp Rear Lights (Canada Only) 8 – 10 Amp Integrated Control Unit, Interior & Exterior Lighting 9 – Blank

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Removal and Installation WARNING: When carrying out maintenance on the starting system be aware that the heavy gauge leads are connected directly to the battery. Make sure the protective caps are in place when maintenance is completed. Failure to follow these instructions may result in personal injury. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. Remove the nut and disconnect the starter solenoid S-terminal eyelet. To install, tighten to 6 Nm (53 lb-in) . 4. Remove the nut and disconnect the starter solenoid B-terminal eyelet. To install, tighten to 12 Nm (9 lb-ft) . 5. Remove the nut and disconnect the starter motor ground cable eyelet. To install, tighten to 20 Nm (15 lb-ft) . 6. Remove the stud bolt, the bolts and the starter motor. To install, tighten to 25 Nm (18 lb-ft) . 7. NOTE: Tighten the upper bolt before tightening the lower fasteners. To install, reverse the removal procedure.

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2. Disconnect all wiring from starter solenoid. Remove starter cable from retainer. Remove starter wiring from guides. Remove guides. 3. Raise and support vehicle. Remove noise insulation panel. See Fig. 3 . Remove left-side insulation panel. See Fig. 4 . Remove brackets/retainers securing power steering pressure line. Place power steering pressure line aside. 4. Remove bolts securing starter. See Fig. 5 . Remove starter. To install, reverse removal procedure. Tighten starter mounting bolt/nuts to specification. See TORQUE SPECIFICATIONS . Fig. 4: Identifying Left-Side Noise Insulation Panel Mounting Points Fig. 5: Removing Starter