Volkswagen Jetta / Bora: Electrical System Manual - part 32

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.

9.8.3

Ribbed belt routing, 2.5l engine

Models with air conditioning system:
1 - Upper idler roller
2 - Belt pulley - Alternator
3 - Lower idler roller
4 - Poly V-belt for alternator and coolant pump
5 - Belt pulley - Air conditioner compressor
6 - Poly V-belt for air conditioner compressor
7 - Belt pulley - Crankshaft
8 - Tensioning roller for air conditioner compressor poly V-belt
9 - Tensioning roller for alternator poly V-belt and coolant pump
10 - Belt pulley - Coolant pump

Jetta 2005 ➤ , Bora 2006 ➤

9. Alternator    

125

Alternator, 1.9 l TDI engine

9.9.1

Assembly overview

1 - Hexagon head collared

bolts

❑ M8x45
❑ 20 Nm

2 - Tensioning element for poly

V-belt
3 - Hexagon head collared

bolts

❑ M8x90
❑ 20 Nm

4 - Compact bracket

❑ For alternator and air

conditioner compressor

❑ Tightening sequence

⇒ page 148

5 - Hexagon head collared

bolts

❑ M10x65
❑ 40 Nm

6 - Hexagon head collared

bolts

❑ M10x45
❑ 40 Nm

7 - Hexagon bolt with washer

and threaded piece

❑ M4x20, M4x15
❑ 2 Nm

8 - Protective cap for alternator
9 - Phillips screws

❑ M4x20
❑ 2 Nm

10 - Protective cap for carbon brushes
11 - Voltage regulator

❑ Removing and installing voltage regulator 

⇒ page 142

12 - Alternator

❑ Removing and installing alternator 

⇒ page 127

13 - Poly V-belt

❑ Checking 

⇒ page 98

 .

Jetta 2005 ➤ , Bora 2006 ➤

126

Removing and installing alternator, 1.9 l

TDI engine

Caution

Disconnecting and connecting the battery as described in the

Workshop Manual 

⇒ page 29

 .

Removing:
Special tools and workshop equipment required
♦ Torque wrench -V.A.G 1331-

♦ Locking pin -T10060 A-

– Disconnect the battery 

⇒ page 29

 .

– Pull engine cover upwards -arrows A- and forwards

-arrow B-.

Jetta 2005 ➤ , Bora 2006 ➤

9. Alternator    

127

♦

All hoses of the charge air system are secured with hose clips

or with quick release couplings. When using quick release

couplings the following points must be observed:

♦

Unlock connection by pulling the securing clamp -arrow-.

♦

Pull hose/tube off without assistance of tools.

– Disconnect connectors -1-.
– Unclip fuel hoses -2- and take charge air hose out.

– Pull vacuum hose -1- off.
– Disconnect connector -2-.
– Remove securing bolt -3-.

– Unbolt securing bolt -arrow-.
– Remove noise insulation ⇒  General Body Repairs, Exterior;

Rep. Gr.  50 ; Body front; Noise insulation .

Jetta 2005 ➤ , Bora 2006 ➤

128