Volkswagen Jetta / Bora: Electrical System Manual - part 25

Torque settings: starter

Threaded connections

 

Torque settings

Starters on automatic, manual gearboxes

M12

75 Nm

Starter on automated shift gearboxes

M10

60 Nm

Earthing wire to starter securing bolt

M8

15 Nm

Wiring retainer on starter securing bolt

M8

15 Nm

Positive wire to starter solenoid switch

M8

15 Nm

Air filter housing to body

 

10 Nm

Earthing wire to automatic gearbox

M8

15 Nm

Jetta 2005 ➤ , Bora 2006 ➤

8. Torque settings: starter    

97

Alternator

Caution

Disconnecting and connecting the battery as described in the

Workshop Manual 

⇒ page 29

 .

9.1

Fastening B+ wire to alternator

Caution

If the B+ wire is not secured with the prescribed torque the

following may occur:

♦ Battery not charge fully.
♦ Vehicle electrics/electronics fail completely (breakdown).
♦ Danger of fires from sparks.
♦ Damage to electronic components and control units due

to excessive voltage.

– The tightening torque for the securing nut of the B+ wire

-arrow- an be found in the following table “Tightening torques”

⇒ page 145

 .

9.2

Checking ribbed belt (poly V-belt)

– Crank engine at vibration damper/belt pulley using a socket.
– Fit ribbed belt (poly V-belt).
♦ Sub-surface cracks (cracks, core ruptures, cross sectional

breaks)

♦ Layer separation (top layer, draw strands)
♦ chassis breakout
♦ Fraying of cord strands
♦ Flank wear (material wear, frayed flanks, flank brittleness

(glassy flanks), surface cracks)

♦ Traces of oil and grease

Caution

It is essential to renew poly V-belt if faults are found. This will

avoid possible break-downs or operating problems.

Jetta 2005 ➤ , Bora 2006 ➤

98

Check alternator -C-

– Connect Vehicle Diagnosis, Testing and Information System

-VAS 5051A- 

⇒ page 281

 .

Select “guided fault finding” in Vehicle Diagnosis, Testing and In‐

formation System -VAS 5051A- .
– Using the “Go to” key, select “Function/component selection”

and the following menu items one after the other:

♦ Body
♦ Electrical System
♦ 27 - Starter, current supply
♦ Electrical components
♦ C - Alternator

9.4

Alternator, 1.6 l injection engine

9.4.1

Assembly overview

1 - Hexagon head collared bolt

❑ M8x108
❑ 23 Nm

2 - Hexagon head collared

bolts

❑ M8x50
❑ 23 Nm

3 - Bracket
4 - Hexagon head collared nut

❑ M8

5 - Hexagon head collared

bolts

❑ M8x45
❑ 52 Nm

6 - Protective cap
7 - Hexagon head collared nut

❑ M8

8 - Cross-head screw

❑ M5x21
❑ 4.5 Nm

9 - Hexagon nut, flat

❑ M8

10 - Plain washer

❑ M5

11 - Phillips screws

❑ M4x19
❑ 2 Nm

12 - Cross-head screw

❑ M4x13

Jetta 2005 ➤ , Bora 2006 ➤

9. Alternator    

99

13 - Voltage regulator

❑ Removing and installing voltage regulator 

⇒ page 142

14 - Alternator

❑ Removing and installing alternator 

⇒ page 100

15 - Poly V-belt

❑ Checking 

⇒ page 98

 .

16 - Compact bracket

❑ For alternator and air conditioner compressor
❑ Tightening sequence 

⇒ page 145

17 - Tensioning element for poly V-belt
18 - Hexagon head collared bolt

❑ M8x90
❑ 23 Nm

9.4.2

Removing and installing alternator, 1.6 l

injection engine

Caution

Disconnecting and connecting the battery as described in the

Workshop Manual 

⇒ page 29

 .

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

♦ Locking pin -T10060 A-

Removing:
– Disconnect the battery 

⇒ page 29

 .

Jetta 2005 ➤ , Bora 2006 ➤

100