Volkswagen Jetta / Bora: Electrical System Manual - part 34

Alternator, 2,0 l TDI engine

9.10.1

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 - Phillips screws

❑ M4x20
❑ 2 Nm

8 - Protective cap
9 - Voltage regulator

❑ Removing and installing

voltage regulator

⇒ page 142

10 - Alternator

❑ Removing and installing alternator 

⇒ page 133

11 - Poly V-belt

❑ Checking 

⇒ page 98

 .

9.10.2

Removing and installing alternator, 2,0 l

TDI engine

Caution

Disconnecting and connecting the battery as described in the

Workshop Manual 

⇒ page 29

 .

Jetta 2005 ➤ , Bora 2006 ➤

9. Alternator    

133

♦ Locking pin -T10060 A-

– Disconnect the battery 

⇒ page 29

 .

– Pull engine cover off upwards -arrows-.

– Pull vacuum hoses off -arrow-.

Jetta 2005 ➤ , Bora 2006 ➤

134

– 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.

– Release poly V-belt by turning the tensioning device with an

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

Jetta 2005 ➤ , Bora 2006 ➤

9. Alternator    

135

– Remove alternator securing bolts -arrows-.

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

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

approx. 4 mm in -direction of arrow-.

Jetta 2005 ➤ , Bora 2006 ➤

136