2005-2007 Volkswagen Jetta Repair Manual
Expert service data for the 1.9L TDI (ALH engine code) Golf and Jetta. Covers engine mechanicals, removal/installation, and technical specifications for reliable performance.
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Models Covered & Key Technical Specifications
Volkswagen Jetta (1999-2008) (ALH Engine) Service Manual
Technical Manual | Engine Mechanical Group.
- Engine Overview: The ALH engine is a 1.9L 4-cylinder TDI. The engine number, consisting of up to nine alphanumeric characters, is located at the engine/transmission joint.
- Technical Data: This manual provides key specifications for the ALH engine.
- Emission Values: Emission values are provided in accordance with D3 standard.
- Engine Assembly: Detailed instructions for engine removal and installation are included.
- Special Tools: Essential tools for engine removal and installation are listed.
- Torque Specifications: Precise torque values are provided for critical bolted connections.
Professional Workshop Service Manual & Technical Specifications
Volkswagen Jetta GL (2005) Service Manual: Engine Mechanical Group
Unit-Designations: Engine Mechanical // Operational-Scope: ALH Engine & TDI Platform // Unit-Designations: Technical Data
Technical Data
| Assessment-Element | Parameters | Context |
|---|---|---|
| Engine Code | ALH | TDI Engine Mechanical |
| Production | 10.97 --> | Golf & Jetta (A4 Platform) |
| Displacement | 1.9 Ltr. | |
| Power | 66/3750 kW at 1/rpm | |
| Torque | 210/1900 Nm at rpm | |
| Bore | 79.5 diameter mm | |
| Stroke | 95.5 mm | |
| Compression ratio | 19.5 | |
| CZ (Cetane rating) | 49 min. | |
| Ignition sequence | 1-3-4-2 | |
| Catalytic converter | x | |
| Exhaust gas recirculation | x | |
| Turbocharging | x | |
| Charge air cooler | x |
Engine Number Locations
Engine number ( "engine code" and "serial number" ) are located at the engine/transmission joint. 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, Removing and Installing
Consistently requiring proper procedures for engine removal and installation is crucial for maintaining vehicle integrity. This manual details the necessary steps, including the disconnection of the battery ground strap, removal of engine covers, battery holder, air filter, and sound dampening tray. It also covers specific instructions for vehicles with turbochargers, such as unclamping the charge air cooler connecting pipe. Torque specifications for various bolted connections and engine/transmission mounts are provided to ensure correct assembly, with special attention paid to alignment edges and the use of specific tools like the engine support bridge.
Special Tools for Engine Removal and Installation
The following special tools are required for engine removal and installation:
- 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
- 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
Torque Specifications
| Bolted connections | Torque specifications |
|---|---|
| Bolts, nuts M 6 | 10 Nm |
| M 8 | 20 Nm |
| M10 | 45 Nm |
| M 12 | 60 Nm |
| Deviation from Front exhaust pipe to turbocharger | 25 Nm |
Engine Mount Assembly
The engine mount assembly requires precise measurements for alignment: Edges - a - (14.0 mm) and - b - (minimum 10.0 mm) must be parallel to each other. Both bolt heads - 1 - must be flush with edge - c -.
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