Volkswagen Jetta / Bora: Electrical System Manual - part 31

♦

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.

9.7.3

Ribbed belt routing, 2.0 l turbo 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 ➤

9. Alternator    

121

Alternator 2.5 l injection engine

9.8.1

Assembly overview

1 - Compact bracket

❑ For alternator and air

conditioner compressor

2 - Multi-point socket head bolt

M8x60

❑ 25 Nm

3 - Multi-point socket head bolt

M8x110

❑ 25 Nm

4 - Hexagon socket head bolt

M8x30

❑ 25 Nm
❑ Qty. 4

5 - Protective cap for alternator
6 - Phillips screws

❑ M4x20
❑ 2 Nm

7 - Protective cap for carbon

brushes
8 - Voltage regulator

❑ Removing and installing

voltage regulator

⇒ page 142

9 - Alternator

❑ Removing and installing

alternator 

⇒ page 127

10 - Poly V-belt

❑ Checking 

⇒ page 98

 .

11 - Hexagon head collared

bolts M8x90

❑ 25 Nm
❑ Qty. 2

9.8.2

Removing and installing alternator, 2.5l

engine

Caution

Disconnecting and connecting the battery as described in the

Workshop Manual 

⇒ page 29

 .

Removing:
Special tools and workshop equipment required

Jetta 2005 ➤ , Bora 2006 ➤

122

♦ Locking pin -T10060 A-

– Disconnect the battery 

⇒ page 29

 .

– Take the engine cover off upwards and forwards.
– Bring lock carrier into service position ⇒  General body repairs,

exterior; Rep. Gr.  50 ; Lock carrier service position

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

-2- off.

Jetta 2005 ➤ , Bora 2006 ➤

9. Alternator    

123

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!

– Remove upper and lower idler roller and tensioning roller for

– Remove alternator securing bolts -arrows-.

– Unscrew wiring bracket from alternator -arrow-.
– Take alternator out upwards.
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.

– Drive threaded sleeves -A- out of the alternator housing for

approx. 4 mm in direction of arrow.

Jetta 2005 ➤ , Bora 2006 ➤

124