Volkswagen Jetta / Bora: Electrical System Manual - part 35

o'clock.

– 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.

9.10.3

Ribbed belt routing, 2,0 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

9.11

Removing and installing ribbed belt

(poly V-belt) pulley on alternator

9.11.1

Removing and installing a ribbed belt

(poly V-belt) pulley with no freewheel

Special tools and workshop equipment required

Jetta 2005 ➤ , Bora 2006 ➤

9. Alternator    

137

♦ Torque wrench -V.A.G 1332-

Removing:
– Take off alternator 

⇒ page 98

 .

– Fit alternator in a vice on fitting points.
– Use socket -VAS 3310- to remove ribbed belt (poly V-belt)

pulley securing nut from alternator shaft.

Installing:
Installation is performed in the reverse order of installation; when

doing this, note the following:
– Tighten threaded connections to specified torque settings

⇒ page 145

 .

9.11.2

Removing and installing a ribbed belt

(poly V-belt) pulley with freewheel, man‐

ufacturer: Bosch

Special tools and workshop equipment required

Jetta 2005 ➤ , Bora 2006 ➤

138

♦ Torque wrench -V.A.G 1332-

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.

Jetta 2005 ➤ , Bora 2006 ➤

9. Alternator    

139

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.

– Insert a socket M10 -1- in the 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

 .

Jetta 2005 ➤ , Bora 2006 ➤

140