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Hi, in response to many requests we'll repair today our Passat 35i
I'll show you how to replace the starter motor
For working at the starter you have always to disconnect the battery
Remove the cable and take care that it will not have accidently contact
At this engine the starter is located between the bell housing of the clutch and the fan
We'll start by removing all cables
The cable from the ignition starter lock is plugged here
Now the contact 50 is off
I remove also this plug from the gear box
Remove the cables from the holder clip
Below is a second cable
The part has been mounted in this direction
Remove the cap of contact 30
The starter is fixed by 2 very long bolts
But take care, the bolts doesn't end here!
The bolts go through here and end in the front engine mount
Thus the have to support the engine when removing the bolts
Don't lift the engine, have just tension in the hangers
Remove the engine ground strap
For unlocking the bolts you'll need some tender force
The second bolts is below the starter
and finally the starter can be removed from the engine
For testing the starter, I fixed it in the vice
Contact 30 I connected to a thick cable directly, which I'll connect later to the plus pole of the battery
Further I make a connection between contact 50 and 30
For the ground I use also a thick cable, connected to the minus pole of the battery
You have seen the problem, the magnetic switch works, but the starter doesn't run at each trial
Maybe the carbon brushes are worn, or the rotor is worn. The starter is very cheap, thus I'll replace it
When installing a new starter, this sleeve should be replaced, too
The sleeve is located behind the starter ring
For removing the sleeve, I'll drill a fitting screw tap in and I pull it out
With brute force it works
For mounting the new sleeve, I made a special tool on the lathe. Coat it with grease
Put grease on the starter sprocket and install the starter
If it enters in position, half job is done
Secure the starter with the upper bolt
If the engine hangs in correct position, the bolt will enter easily
Mount also the lower bolt
Fasten the bolts with 60 Nm
and the same for the lower one
Mount the ground strap
Install all the cables
The big plus cable comes on the bolt here and then the thin cable
Mount the protection cap and the *** over the cable
Check all again - all is fine
All is working
The repair is done, the starter works
Bye, bye, see you in our next vide�