1999-2008 Volkswagen 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)

1999-2008 Volkswagen Jetta Service & Repair Manual

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