Volkswagen Jetta / Bora: Electrical System Manual - part 33

– Disconnect connector of charge air pipe -arrow-.
– Take charge air pipe out upwards.

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

-2- off.

– Unscrew B+ wiring -arrow- off alternator.
– Pull fuel filter off the retainer and place to side (fuel hoses re‐

main connected).

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.

Jetta 2005 ➤ , Bora 2006 ➤

9. Alternator    

129

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

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

– Remove alternator securing bolts -arrows-.

– Unscrew wiring bracket from alternator -arrow-.
– 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.

Jetta 2005 ➤ , Bora 2006 ➤

130

approx. 4 mm in -direction of arrow-.

– Position wiring bracket -arrow- on rear of generator at 9

o'clock.

Note

♦

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:

♦

Fit hose/tube without assistance of tools.

♦

Check for secure fit of the lugs -arrow-.

– 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.

Jetta 2005 ➤ , Bora 2006 ➤

9. Alternator    

131

Ribbed belt routing, 1.9 l TDI engine

Models without air conditioning system:
1 - Tensioning roller
2 - Ribbed belt pulley - Alternator
3 - Poly V-belt
4 - Ribbed belt pulley - Crankshaft

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 ➤

132