i done this when i first brought me car but just found the description of how to do it and thought id share it. many mk4 usually 1.8t have this issue n most ppl buy new starters but it is actually clutch dust that makes them do this 1.8T specific, but almost identical for all Mk4s This procedure goes through the steps of removing and cleaning the starter on a Mk4 Golf/Jetta. Mk4 starters have a tendency to get gummed up, which can result with a grinding noise (ie. the starter motor not disengaging from the flywheel) during cold start-ups.
The total process should take less than 2 hours, and is not very complicated.
Tools required: - Ratchet + extensions
- 7mm, 10mm, 13mm and 18mm sockets. You'll definitely need a deep 18mm socket
- Phillips screwdriver
- Torx sockets sized 25
- Parts/tools cleaner (spray can)
- Grease! (I used some good 'ol high temp wheel bearing grease)
Step by Step: Step 1: Remove battery, and surrounding plastic. This involves:
- Disconnect both positive and negative battery terminals.
- Remove 10mm screw on the backside of battery (which airbox is mounted to)
- Remove plastic 'wire cover' on backside of battery cover (between the battery and airbox) by pulling it up and out.
- Remove plastic shroud underneath terminal box, by flipping it up and then pulling it out.
- Loosen (or remove) 13mm nut of the 'clamp' on the bottom front lip of the battery. This is a lot easier if you remove the front "air duct" behind the drivers side headlight. Remove the 2 phillips screws, and just slide "up" the plastic cover to remove it.
- Remove battery, including battery blanket, from the engine and put it to the side.
Note: I had my battery removed for a good 3.5 hours (I had to eat dinner during this procedure!) and did not need the radio code when I was done.
Step 2: Remove battery tray. This involves removing the four 10mm nuts on the bottom of it, and lifting it out.
Step 3: Admire your starter motor, in all it's glory! Dive in and remove the black plastic cap that covers the main power cable to the starter
Step 4: Disconnect the main alternator connector, the connector on the back of the alternator (squeeze metal clips on side of connector and pull it off) and remove 13mm nut that connects the power cable to the starter assembly.
Slide off the main power cable and move it to the side.
Step 5: Jack up the car, and remove the front shroud that shields the bottom front of the engine compartment. There are 4 Torx bits holding it in place.
Step 6: While on your back, locate the starter and remove the 13mm bolt that connects it to the metal bracket. Slide the bracket out of the way.
Step 7: From the top of the engine, remove the 13mm nut that is HIDDEN underneath the plastic wire shroud. As you can see in the picture, I found a long extension helped get access to this bolt.
Step 8: Remove plastic shroud, clamped around the wires. You'll have to start by 'sliding out' the other end of the main black alternator connector from the shroud. This shroud was previously connected to the starter by the bolt removed in the above step. You'll have to slide the unit a bit to the right, and then twist it off. This may take a bit of jiggling. I've included a picture of the shroud removed, so you can see what you're up against.
Step 9: Remove the main upper starter bolt. From the top of the engine, if you pull the wires out of the way you can just see where it is (see picture).
Grab your 18mm deep socket and extension, and remove it! This sucker is on tight (don't say I didn't warn you!) and is about 5" long.
Step 10: Remove the lower starter bolt. Again, 18mm deep socket, from the underside of the car.
Step 11: Pull out the starter! Once you remove the two main long bolts, the starter will slide out pretty easily.
Step 12: Time to clean it! Spray the top of it with the parts cleaner to get all the clutch dust off of it. One half of mine was pretty dirty, and the other half wasn't too bad at all. Spray all the crap off of the gear, too.
Step 13: Disassemble starter motor from starter transmission. There are two 7mm bolts on the back of it, keeping the two parts together. These are pretty long! Also remove the bolt attaching the ground strap.
Step 14: Take the top plastic cover off of the starter transmission, by simply pulling it off. Take a look at the nifty planetary gearset!
As you can see in the pics, mine weren't terribly dirty. I've heard that they can be a lot worse in TDI's. Still, there was a lot of debris in mine that definitely can't be helping things! Start off by cleaning the plastic cover you popped off with parts cleaner.
Step 15: Remove the outer gear ring by sliding it up. The three rubber 'feet' on the sides will come off easily. Clean off this gear!
Step 16: Pull off the three small gears, and clean them off. A toothbrush may help with this.
Step 17: If you pull out the entire plastic casing, you can expose a spiral gear underneath. You can't remove this part, but you can expose it enough to clean it off!
Step 18: Remove the small metal cover on the back of the starter motor by unscrewing the two phillips screws. Clean off all the gunk inside! There is a washer on there too, so remove it and clean it off. Regrease these parts, put some grease inside the metal cap, and re-attach it to the back of the starter motor. Mmmmmmm, grease!
Step 19: Double check to make sure you've cleaned up all your gears (including the area around the spiral gear)!
Step 20: Reassemble gears, and grease up! Put the 3 planetary gears back on, along with the outer ring gear (don't forget to reattach the black rubber feet).
Regrease
EVERYTHING. Put some on all the small gears (don't forget inside them too, 'cuz there are some small bearings in there!), the outer ring gear, and put some on the spiral gear too.
I found you could work the grease down the spiral gear by pulling it in and out, adding new grease as it works its way in. Don't forget to put a blob of grease right down the middle of the planetary gear set unit (in the little hole) and a light coating on the top of the plastic case.
Step 21: Push the plastic housing back into the starter transmission (you may have to rotate it a bit so it lines up right), and pop the top of the case back onto the unit (use the bolt holes to line up the cap with the rest of the unit). Reattach the starter motor to the starter transmission with the loooooong 7mm screws. Don't forget about the bolt for the ground strap too.
Honest, it's pretty hard to screw up the reassembly of this thing. Admire how smoothly the main starter gear rotates with it's brand new grease job! (yes, it will only rotate one way).
Step 22: Re-attach starter to transmission. The big long starter bolts (18mm) have a torque spec of 48 ft-lbs (65Nm). The only real pain in the butt when reinstalling is putting the plastic wire shroud back on. Just pry it open, and force it around the wires...then slide it over it's support bolt. Don't forget to reconnect
ALL connectors, and the main power cable! Finally, put that black plastic cap back overtop of the power cable attachment bolt.
Step 23: Re-install battery. Take your time. Make sure it's seated properly before buttoning everything up.
Conclusion: The morning after I did this procedure, my cold-start grinding noise was gone. I'd say it was a success! Looks like it doesn't take much crap inside of the starter for it to bind and cause the grinding, so this is probably a job to do every couple of years (oh boy!)
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