Volkswagen Jetta / Bora: Electrical System Manual - part 26

– Disconnect connector of DF wiring -1- and pull protective cap

-2- off.

– Unscrew B+ wiring -arrow- off alternator.

Caution

Mark top and direction of rotation of poly V-belt before remov‐

ing. When installing observe direction of rotation marked on

removal. Installing opposite to the direction of rotation leads to

belt damage!

– Mark direction of rotation of poly V-belt.

– Release poly V-belt by turning the tensioning device with an

open-ended spanner AF 16 in -direction of arrow-.

– Lock tensioning element with retaining pin -T10060 A- .
– Remove ribbed belt.

Jetta 2005 ➤ , Bora 2006 ➤

9. Alternator    

101

ing nut -2-.

– Unbolt securing bolts -arrow-.
– Take hose retainer together with tensioning element out of the

vehicle.

– Remove alternator securing bolts -arrows-.

– Unscrew wiring bracket -arrow- from alternator.
– Remove alternator.
Installing:
Installation is carried out in the reverse order. When installing,

note the following:

Caution

♦ When reinstalling used ribbed belts (poly V-belts) observe

the direction of rotation marked on removal!

♦ Ensure, before installing ribbed belt, that all ancillaries (al‐

ternator, air conditioner compressor) are secured tightly.

♦ Ensure ribbed belt (poly V-belt) is seated correctly in belt

pulley when installing.

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102

approx. 4 mm in -direction of arrow-.

– Position wiring bracket -arrow- on rear of generator at 3

o'clock.

– Tighten threaded connections to specified torque settings

⇒ page 145

 .

Caution

Observe  instructions  on  connecting  battery  terminals

⇒ page 4

 .

– Connect the battery 

⇒ page 29

 .

– Start the engine and check belt running.
– Switch off the engine.

9.4.3

Ribbed belt routing, 1.6 l injection en‐

gine

Models with air conditioning system:
1 - Tensioning roller
2 - Ribbed belt pulley - Alternator
3 - Ribbed belt pulley - Air conditioner compressor
4 - Poly V-belt
5 - Ribbed belt pulley - Crankshaft

Jetta 2005 ➤ , Bora 2006 ➤

9. Alternator    

103

Alternator, 1.6 l FSI engine

9.5.1

Assembly overview

1 - Hexagon bolt

❑ 40 Nm

2 - Washer
3 - Idler roller
4 - Washer
5 - Valve gear casing
6 - Hexagon head collared nut

❑ M8

7 - Cross-head screw

❑ M5x21
❑ 4.5 Nm

8 - Hexagon nut, flat

❑ M8

9 - Plain washer

❑ M5

10 - Protective cap
11 - Phillips screws

❑ M4x19
❑ 2 Nm

12 - Cross-head screw

❑ M4x13
❑ 2 Nm

13 - Voltage regulator

❑ Removing and installing

voltage regulator

⇒ page 142

14 - Alternator

❑ Removing and installing alternator 

⇒ page 105

15 - Poly V-belt

❑ Checking ribbed belt (poly V-belt) 

⇒ page 98

16 - Hexagon head collared bolts

❑ M8x90
❑ 23 Nm

17 - Hexagon head collared bolts

❑ M8x50
❑ 25 Nm

18 - Tensioning element
19 - Bracket

❑ For tensioning element and air conditioner compressor

20 - Hexagon head collared bolt

❑ M10x50

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