Replacing the starter motor on a Volkswagen Golf III TDI

Hello.
My starter motor seems to be burned out. When I tried to start it, all that came out was a cloud of smoke...

However, the car started immediately as it was rolling forward.
When you turn the key to the "start" position, the starter motor doesn't do anything at all ;( Is there a way to check if it's burned out? It certainly smells like it.


Question: Is it possible to replace the starter motor without a lift? What needs to be disassembled? Does anyone have a guide for me?

Does the transmission need to be supported?

According to AKTE, the starter motor type 02A 911 024D is the correct one. Are there any alternatives? What do you think about buying used starters from online marketplaces?

The vehicle is a 1997 Volkswagen Golf III TDI with a manual transmission and engine code AHU.

Thank you.

Peter.

The starter motor on the Golf III is a bit awkwardly positioned. It's located at the front of the transmission. To remove it, you need to remove the front engine mount. In my opinion, a motor bridge is essential for safe working, because supporting the engine from below often causes the transmission to twist slightly, which can prevent the screws from aligning properly. Therefore, use a bridge to absorb the impact on both the motor and the transmission.

After that, you can loosen the front engine mount, which also secures the starter motor, using the screws.

It's fairly self-explanatory, though.


Very important: Remove the battery or completely disconnect it, meaning both the positive (+) and negative (-) terminals. The starter cable is not insulated, which means that it can cause a significant spark if it comes into contact with the car body while the battery is connected.



If the starter motor is completely unresponsive, it likely indicates burnt-out windings or worn-out carbon brushes, which can ultimately lead to the connection wires of the brushes being welded to the commutator.

In my opinion, it doesn't make much sense to repair a total failure; it's better to buy a used part or a refurbished part from BOSCH.

For the latter, you have a 2-year warranty, and you can be sure it will last that long. However, they cost a bit, and depending on your purchasing conditions, the starters cost between €150 and €250 net.

Personally, considering the age of the vehicle, I would buy a used car from a platform like www.callparts.de rather than a certified recycler.

Benefit: You get a 1-year warranty and can be sure you're buying a working part.


"In online auctions, you often find items being sold that were supposedly "working until they were disassembled"... except, of course, for parts dealers, who operate here as well – they also offer warranties."

With private purchases, you always run this risk... and unfortunately, I've experienced it myself.



The starter motor, part number 02A 911 024D, currently costs around €530 from VW.

The replacement part from Valeo has a net list price of €204 without discounts, while the Bosch replacement starter motor, with Bosch part number 0 986 016 980, costs approximately €280 net.

All of this is subject to the condition that the part number you researched is correct.


Considering these prices, I think it's not worthwhile to buy a new part for such an old vehicle. Instead, it's advisable to go to a scrapyard, where, according to my research, starter motors are available for between €40 and €150, for example at Callparts.


Good luck with the repair .

Quote:

The starter motor on the Golf III is a bit awkwardly designed. It's located at the front of the transmission. To remove it, you need to remove the front engine mount. In my opinion, an engine support bridge is essential for safe work, because supporting it from below often causes the transmission to twist slightly, which means the screws won't line up anymore... Therefore, use the bridge to absorb the impact on both the motor and the transmission.

That's right. If necessary, it can also be done this way, by catching the engine from below.

Hello.
Thank you for the helpful answers.

As you mentioned, I would only consider a used part as a replacement. Especially since there's no rush.

Can a used starter motor be tested by connecting it to 12V, or will it simply "work" without any load?
A similar part might have been used in newer vehicles. That would significantly increase the chances of finding a reasonable used part .

Unfortunately, I don't have a motor mount. If the gears slip, can a timer be used to bring them back into the correct position?


Thank you.

Peter.

Quote:

Unfortunately, I don't have a motor mount. If the gears slip, can a timer be used to bring them back into the correct position?

Yes, it's possible, but it's a bit fiddly. When supporting the engine from below with a jack, you should relieve enough pressure so that the screws can be easily turned.

Hi,
You only need to run the starter motor for a short time. Otherwise, the speed reaches a maximum value, which is like when the pinion gear isn't properly engaged.
hg
Herbert.

Starter motor testing:

- Securely clamp it in the vise.
- Connect the ground cable (jumper cable!!) to the starter motor housing.
- Connect the positive terminal of the jumper cable to the screw-type positive terminal.
- Connect a cable with a cross-sectional area of 2.5mm² or greater to the positive terminal of the magnetic switch contact (connector).

You won't break anything by doing that; I've always tested my starters this way after repairs...


Used part:

- Why don't you check out Callparts? They have a lot of starters for the Golf III. According to my records, the starter motor with your part number was also used in the Golf IV.

Hi.
Check this out: www.fm-autoteile.de

The Lima part I got for my Seat back then was practically brand new.

Best regards, Frank.

bindpe wrote:

Hello. Finally managed to remove the starter motor. It looks like only this copper cable is defective. Is there a way to fix this? Can it be repaired by soldering? thank you

Hello!

Please continue here and don't start a new topic (and please don't use "..." 10 times).
Your aforementioned. I have deleted the post.

Regarding the issue: A photo would be helpful, although the copper cable itself is unlikely to be damaged.

Best regards from Munich!

Quote:

It looks like only this copper cable is defective. Can it be repaired somehow? Can it be soldered?

It's theoretically possible, but very difficult to implement. Soldering won't work in this case.

I would replace that part.

@DB This is the cable (or braided wire) that carries power from the magnetic switch to the starter motor – and when it's defective, it usually disintegrates. There's nothing left of it.