Volkswagen Jetta / Bora: Electrical System Manual - part 36

Removing and installing a ribbed belt (poly V-belt) pulley with freewheel,

manufacturer: Valeo

Special tools and workshop

equipment required
♦ Adapter -VAS 3400-
♦ Torque wrench -V.A.G

1332-

♦ TORX key -V.A.G 1603/1-

Removing:
– Take off alternator 

⇒ page 98

 .

– Fit alternator in a vice on fitting points.
– Take protective cap off ribbed belt (poly V-belt) pulley with

freewheel.

Note

The thread on the alternator shaft is a left-hand thread, i.e. turn

to right when loosening and to left when tightening the threaded

joint.

– Fit adapter -VAS 3400- in the ribbed belt (poly V-belt) pulley

with a freewheel of the alternator with a ring spanner AF 17.

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9. Alternator    

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ring spanner.

– Hold the ribbed belt (poly V-belt) pulley with a freewheel with

the hand and turn the drive shaft of the alternator until the rib‐

bed belt (poly V-belt) pulley with a freewheel can be taken off.

Installing:
Installation is carried out in the reverse order. When installing,

note the following:
– At first screw the ribbed belt (poly V-belt) pulley with a free‐

wheel on the drive shaft of the alternator by hand to limit stop.

The torque wrench -V.A.G 1332- must be rearranged before in‐

stalling the ribbed belt (poly V-belt) pulley with a freewheel as

follows:

– Release socket -1- and pull off grip -2-.
– Turn the torque wrench grip -2- through 180 degrees and re‐

insert socket drive.

– Set torque wrench direction of rotation on socket to left.

– Fit TORX key -V.A.G 1603/1- into alternator shaft.
– Counter-hold adapter -VAS 3400- with ring spanner, AF 17.
– Tighten the ribbed belt (poly V-belt) pulley with a freewheel by

turning the alternator drive shaft to left using torque wrench -

V.A.G 1332- .

– Tighten threaded connections to specified torque settings

⇒ page 145

 .

9.12

Voltage regulator for alternator

9.12.1

Removing and installing voltage regula‐

tor, manufacturer: Bosch

Special tools and workshop equipment required

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Removing:
– Remove alternator.
– Remove securing bolt and nuts -arrows- and take protective

cap off alternator.

– Remove securing bolts for voltage regulator -arrows-.
– Remove voltage regulator from alternator.
Installing:
Install in reverse order of removal.
– Tighten threaded connections to specified torque settings

⇒ page 145

 .

9.12.2

Removing and installing voltage regula‐

tor, manufacturer: Valeo

Special tools and workshop equipment required
♦ Torque wrench -V.A.G 1783/-

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ternator.

– Remove securing bolts for voltage regulator -arrows-.
– Remove voltage regulator from alternator.
Installing:
Installation is carried out in the reverse order. When installing,

note the following:

– Release locking lugs -arrow- and pull protective cap off voltage

regulator.

– Push voltage regulator carbon brushes in housing of voltage

regulator and place voltage regulator in alternator.

– Tighten threaded connections to specified torque settings

⇒ page 145

 .

– Push protective cap into guides -arrows- until it audibly en‐

gages.

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