1999-2008 Jetta Service & Repair Manual

ENGINE 1.9 Liter 4-Cyl. 2V TDI Engine Mechanical, Engine Code(s): ALH - Golf & Jetta (A4 Platform) 00 - GENERAL, TECHNICAL DATA TECHNICAL DATA Engine number locations Fig. 1: Locating Engine Number Courtesy of VOLKSWAGEN UNITED STATES, INC. The engine number ( "engine code" and "serial number" ) are located at the engine/transmission joint - arrow -. The engine number consists of up to nine characters (alphanumeric). The first part (maximum 3 letters) represents the "engine code" , the second (six digit) is the "serial number". If more than 999,999 engines with the same engine code are produced, the first of the six characters is replaced with a letter. In addition, a sticker with "engine code" and "serial number" is affixed to the timing belt cover. The engine code is also included on the vehicle data plate. Engine data Code letters ALH Production 10.97 --> 2005 Volkswagen Jetta GL ENGINE 1.9 Liter 4-Cyl. 2V TDI Engine Mechanical, Engine Code(s): ALH - Golf & Jetta (A4 Platform) 2005 Volkswagen Jetta GL ENGINE 1.9 Liter 4-Cyl. 2V TDI Engine Mechanical, Engine Code(s): ALH - Golf & Jetta (A4 Platform)

10 - ENGINE - ASSEMBLY ENGINE, REMOVING AND INSTALLING Engine, removing and installing Special tools, testers and auxiliary items required Emission values in accordance with D3 standard Displacement ltr. 1.9 Power kW at 1/rpm 66/3750 Torque Nm at rpm 210/1900 Bore diameter mm 79.5 Stroke mm 95.5 Compression ratio 19.5 CZ (Cetane rating) min. 49 Ignition sequence 1-3-4-2 Catalytic converter x Exhaust gas recirculation x Turbocharging x Charge air cooler x 2005 Volkswagen Jetta GL ENGINE 1.9 Liter 4-Cyl. 2V TDI Engine Mechanical, Engine Code(s): ALH - Golf & Jetta (A4 Platform)

Fig. 2: Identifying Special Tools - Engine, Removing And Installing (1 Of 2) Courtesy of VOLKSWAGEN UNITED STATES, INC.  Engine sling 2024 A  Engine/transmission support T10012  Holding fixture VW 313  Holding fixture VW 540  Shop crane V.A.G 1202 A  Drip tray for workshop crane V.A.G 1306 Special tools, testers and auxiliary items required 2005 Volkswagen Jetta GL ENGINE 1.9 Liter 4-Cyl. 2V TDI Engine Mechanical, Engine Code(s): ALH - Golf & Jetta (A4 Platform)

Fig. 3: Identifying Special Tools - Engine, Removing And Installing (2 Of 2) Courtesy of VOLKSWAGEN UNITED STATES, INC.  Torque wrench V.A.G 1331  Torque wrench V.A.G 1332  Engine/transmission jack V.A.G 1383 A  Hose clip pliers V.A.G 1921  Step ladder VAS 5085  Grease G 000 100  Bolt M10x25/8.8 (not shown)  Cable tie (not shown) 2005 Volkswagen Jetta GL ENGINE 1.9 Liter 4-Cyl. 2V TDI Engine Mechanical, Engine Code(s): ALH - Golf & Jetta (A4 Platform)

Engine, removing Work procedure  With ignition switched off disconnect battery Ground (GND) strap.  All cable ties which are opened or cut open when removing engine, must be replaced in the same position when installing engine.  Remove engine cover.  Remove battery and battery holder.  Remove air filter.  Remove sound dampening tray  For vehicles with turbocharger. Unclamp connecting pipe between charge air cooler and exhaust pipe at exhaust pipe. NOTE:  To perform work, the Ground (GND) cable must be disconnected from battery. Check whether a coded radio is installed. If so, obtain anti-theft coding beforehand.  The engine is removed downward together with the transmission.  All cable ties which are opened or cut open when removing engine, must be replaced in the same position when installing engine. CAUTION: When doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues:  Route lines of all types (e.g. for fuel, hydraulic, EVAP canister system, coolant and refrigerant, brake fluid, vacuum) and electrical wiring so that the original path is followed.  Ensure sufficient clearance to all moving or hot components. 2005 Volkswagen Jetta GL ENGINE 1.9 Liter 4-Cyl. 2V TDI Engine Mechanical, Engine Code(s): ALH - Golf & Jetta (A4 Platform)

 Clamp off fuel supply line and return line at fuel filter.  Remove slave cylinder for hydraulic clutch: Refer to 30 CLUTCH  Disconnect selector mechanism from transmission: Refer to 34 MANUAL TRANSMISSION - CONTROLS, HOUSING  Vehicles with automatic transmission: Disconnect selector lever cable from transmission: Refer to 37 AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for 01M Transmissions, or 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for 09A transmissions  Remove noise insulation pan, along with left and right sides: Refer to 50 BODY, FRONT  Drain engine coolant.  Remove connectors from thermal switch and radiator fan.  Disconnect radiator coolant hoses at engine with hose clip pliers V.A.G 1921. Fig. 4: Identifying Pendulum Support & Bolts CAUTION:  The fuel or fuel lines in fuel system can become very hot (danger of scalding)!  In addition, the fuel system is under pressure! Before opening the system, place rags around the connection area and release pressure by carefully loosening the connection!  Wear protective goggles and protective gloves when working on the fuel system! 2005 Volkswagen Jetta GL ENGINE 1.9 Liter 4-Cyl. 2V TDI Engine Mechanical, Engine Code(s): ALH - Golf & Jetta (A4 Platform)

Courtesy of VOLKSWAGEN UNITED STATES, INC.  Remove pendulum support bolts - arrows -.  Disconnect vacuum and breather hoses from engine.  Disconnect generator and starter wiring from transmission, and move them to one side for clearance.  On vehicles with all-wheel drive, remove front driveshaft tube: Refer to 39 FINAL DRIVE, DIFFERENTIAL for 01M transmissions, or 39 - FINAL DRIVE, DIFFERENTIAL for 09A transmissions  Remove exhaust pipe  Remove ribbed belt.  Remove power steering pump from bracket and place to side; hoses remain connected: Refer to 48 STEERING  Disconnect all electrical connections as necessary from engine and lay aside.  Remove right drive axle and unbolt left drive axle at transmission: Refer to 40 FRONT SUSPENSION  Remove securing clamps for power steering pressure line.  Set engine/transmission support T10012 onto engine/transmission jack V.A.G 1383 A. Fig. 5: Identifying Engine Bracket T10012 & Engine/Transmission Jack V.A.G. 1383A Courtesy of VOLKSWAGEN UNITED STATES, INC. 2005 Volkswagen Jetta GL ENGINE 1.9 Liter 4-Cyl. 2V TDI Engine Mechanical, Engine Code(s): ALH - Golf & Jetta (A4 Platform)

 Fasten engine/transmission support T10012 to cylinder block with nut and bolt M10x25/ 8.8 to approx. 40 Nm.  Slightly lift engine and transmission using engine/transmission jack V.A.G 1383 A. Fig. 6: Locating Engine Carrier Bolts (Engine Side) Courtesy of VOLKSWAGEN UNITED STATES, INC.  Remove engine mount (engine side) from engine bracket - arrows - working from above. Fig. 7: Locating Engine Carrier Bolts (Transmission Side) Courtesy of VOLKSWAGEN UNITED STATES, INC.  Remove engine/transmission mount from transmission bracket - arrows - working from above. NOTE:  Use step ladder VAS 5085 to remove bolts. 2005 Volkswagen Jetta GL ENGINE 1.9 Liter 4-Cyl. 2V TDI Engine Mechanical, Engine Code(s): ALH - Golf & Jetta (A4 Platform)

 Carefully lower engine/transmission assembly.  While lowering, carefully guide power steering lines past transmission. Engine, securing to assembly stand Work procedure  Remove transmission from engine. Vehicles with automatic transmission  Secure torque converter to prevent it from "falling out" after engine and transmission are separated. All vehicles NOTE:  Carefully guide engine with transmission, when lowering, to prevent damage to the body. NOTE:  To work on the engine outside of the vehicle, secure engine to assembly stand using holding fixture VW 540 on holding fixture VW 313. 2005 Volkswagen Jetta GL ENGINE 1.9 Liter 4-Cyl. 2V TDI Engine Mechanical, Engine Code(s): ALH - Golf & Jetta (A4 Platform)

Fig. 8: Identifying Engine Sling 2024 A Attached To Engine Courtesy of VOLKSWAGEN UNITED STATES, INC.  Attach engine sling 2024 A as follows and lift engine from engine/transmission jack V.A.G 1383 A using workshop crane. Belt pulley side: 2nd hole in hook at position 2 Flywheel side: 3rd hole in hook at position 8  Fasten engine using holding fixture VW 540 to holding fixture VW 313. Installation notes: Installation is in reverse order of removal. Note the following:  Check clutch release bearing for wear and replace if necessary.  Lightly grease clutch release bearing, guide sleeve for release bearing and input shaft splines with G 000 100.  Check whether alignment sleeves for centralizing engine/transmission are in cylinder block, install if necessary.  When installing the assembly, ensure clearance to the drive axle.  Align engine and transmission mountings. Refer to Engine and transmission mounts, aligning .  Install drive axles: Refer to 40 FRONT SUSPENSION  Install front exhaust pipe. Refer to Exhaust system components, removing and installing , Exhaust system components, removing and installing.  On vehicles with all-wheel drive, install the front drive shaft tube: Refer to 39 CAUTION: Secure ALL hooks and locating pins with lock pins! NOTE:  Positions marked 1 to 4 on the bar must be located toward the pulley end of the engine.  The holes in the hooks are counted up from the hook. 2005 Volkswagen Jetta GL ENGINE 1.9 Liter 4-Cyl. 2V TDI Engine Mechanical, Engine Code(s): ALH - Golf & Jetta (A4 Platform)

1999-2008 Jetta Service & Repair Manual

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