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Part five:Replacing the starter
Tools required: Lifting jack, two jack stands, 12 point 8mm tool (I think it's an 8mm), various metric sockets, plank of wood, dielectric grease, multipurpose grease, your brain and Beer.
-Pop the hood, disconnect the battery and then the starter's connections.
-Then raise the car and put it on the jack stands. Stands should ALWAYS be used in pairs.
-Take the plank of wood, put it between the oil pan and jack. You have to support the engine before removing the starter. Supporting it from the oil pan is a good idea but you have to spread the weight if you don't want to dent the pan.
-Lift the engine slightly! You just have to support the weight of it.
-Drink a Beer
-From the engine bay, loosen the first starter bolt (12 point). Don't remove it yet. There are three bolts holding the starter to the tranny.
-Then remove the two bolts from under the car (one is a standard bolt, the other is a 12 point).
-Back to the engine bay, remove the first bolt you loosened and hold the starter so it doesn't fall. You'll notice that these bolts are also holding the front motor mount to the engine! Hence the "support the engine" thing.
-Next replace the starter's bushing (see above in troubleshooting)
-Take your new "upgraded" starter, lube the end of the shaft with multipurpose grease and put it in place. It's a good idea to seal the tranny and starter with sealant (RVT...). Don't let it hang from the tranny without bolts, you could damage your newly installed bushing. Install the top bolt. You might have to fiddle a bit with the mount to thread it. Don't tighten it yet.
-From under, install the two bolts. Again you might have to fiddle with the mount or even the jack supporting the engine. Once they are in, torque all the bolts to 43lb.
-Remove the jack from under the engine and drop the car on it's wheels.
-Reconnect the battery and starter. Use dielectric grease on the connections.
-Double check everything then start the car!!!
-Have another Beer. You are done.
I know it's an extremely long read. I may have forgot something or some things aren't right. If so just tell me and I'll edit my post.
http://forums.vwvortex.com/showthread.php?2359900-DIY-Starter-Upgrade-Repair-troubleshooting-Replacement-%28manual-tranny%29