1.9L - TDI Engine Mechanical - ALH (A4 Platform)

• 00 - General, Technical Data
  • Technical data
    • Engine number locations
    • Engine data
• 10 - Engine - Assembly
  • Engine, removing and installing
    • Engine, removing and installing
    • Engine, removing
    • Engine, securing to assembly stand
    • Installation notes:
    • Torque specifications
    • Engine and transmission mounts, aligning
    • Engine and transmission mounts, torque specifications
      • Engine mount
      • Transmission mount
      • Pendulum support
    • Vehicles with air conditioning, additional information and removal instructions
• 13 - Engine - Crankshaft, Cylinder Block
  • Engine, disassembling and assembling
    • Engine, disassembling and assembling
    • Overview
      • Part I
      • Part II
      • Versions of securing bolts for injection pump sprocket
    • Idler roller, removing and installing
    • Ribbed belt, removing and installing
      • Work procedure
      • Ribbed belt routing
    • Semi-automatic toothed belt tensioning roller, checking
      • Test sequence
  • Sealing flanges and pressure plate/flywheel/drive plate, removing and installing
    • Sealing flanges and pressure plate/flywheel/drive plate, removing and installing
    • Crankshaft seal (ribbed belt side), replacing
      • Notes
      • Removing
      • Installing
      • Installing PTFE-version sealing ring
    • Drive plate, removing and installing
    • Sealing flange (front), removing and installing
  • Crankshaft, removing and installing
    • Crankshaft, removing and installing
      • Notes
      • Crankshaft dowel pin projection, checking
    • Crankshaft dimensions
  • Piston and connecting rod, disassembling and assembling
    • Piston and connecting rod, disassembling and assembling
      • Notes
      • Checking piston ring gap
      • Checking ring to groove clearance
      • Checking cylinder bores
      • Installed position of piston and piston/cylinder allocation
    • Piston position at TDC, checking
      • Notes
      • Identification of cylinder head gasket
    • Piston and cylinder dimensions
• 15 - Engine - Cylinder head, Valvetrain
  • Cylinder head, assembly overview
    • Cylinder head, assembly overview
      • Notes
      • Checking Cylinder Head For Distortion
      • Cylinder Head Gasket Identification
    • Toothed belt, removing, installing and tensioning
      • Notes
      • Removing
      • Installing
    • Cylinder head, removing and installing
      • Notes
      • Removing
      • Installing
    • Compression pressures, checking
      • Notes
      • Work sequence
  • Valvetrain, assembly overview
    • Valvetrain, assembly overview
      • Notes
      • Camshaft axial play, checking
      • Installed position of camshaft bearing caps
      • Valve dimensions
      • Camshaft identification, valve timing
    • Valve seats, reworking
    • Valve guides, checking
    • Valve guides, replacing
    • Valve stem seals, replacing
    • Camshaft, removing and installing
      • Notes
      • Removing
      • Installing
    • Hydraulic valve lifters, checking
• 17 - Engine - Lubrication
  • Lubrication system components
    • Lubrication system components
    • Engine oil
      • Notes
      • Oil system capacity:
    • Lubrication system components, removing and installing
      • Part I
      • Part II
        • Notes
        • Markings on oil dipstick
      • Part III
      • Oil supply line, disassembly and assembly
    • Oil pan, removing and installing
    • Oil pressure and oil pressure switch, checking
• 19 - Engine - Cooling system
  • Cooling system components, removing and installing
    • Cooling system components, removing and installing
    • Cooling system components, body side
    • Cooling system components, engine side
    • Coolant hose connection diagram
      • Engine code: ALH (with manual transmission)
      • Engine code ALH
    • Cooling system, draining and filling
    • Radiator, removing and installing
      • Notes
      • A/C system additional information and assembly
    • Coolant pump, removing and installing
      • Notes
      • Removing
      • Installing
    • Coolant thermostat, removing and installing
• 20 - Fuel Supply
  • Fuel supply system components, removing and installing
    • Fuel supply system components, removing and installing
    • Safety precautions when working on fuel supply system
    • Rules for cleanliness
    • Fuel tank with attachments, assembly overview
      • Vehicles with all wheel drive (AWD)
        • Notes
        • Installed location of fuel pump flange and fuel level sensor
        • Checking breather valve
      • Vehicles with front wheel drive (FWD)
        • Notes
        • Installed location of the fuel gauge sender
        • Checking breather valve
    • Fuel filter, assembly overview
    • Fuel tank, removing and installing
      • Notes
      • Removing
      • Installing
    • Fuel Pump (FP), removing and installing
      • Notes
      • Removing
      • Installing
    • Fuel pump, checking
      • Notes
      • Function and voltage supply, checking
    • Suction jet pump, removing and installing
      • Notes
      • Work procedure
    • Accelerator pedal mechanism, assembly overview
      • Vehicles with adjustable throttle position sensor
      • Vehicles with non-adjustable throttle position sensor
    • Throttle position (TP) sensor, checking
      • Vehicles with adjustable throttle position sensor
      • Vehicles with non-adjustable throttle position sensor
    • Adjusting Throttle Position (TP) sensor
• 21 - Turbocharger, G-Charger
  • Charge air system with turbocharger
    • Safety precautions
    • Rules for cleanliness
    • Turbocharger with attachments
      • Notes
      • Hose connections with connection couplings
      • Turbocharger system, assembly overview
    • Charge air cooler components, assembly overview
    • Turbocharger line connections
  • Charge pressure system, checking
    • Charge pressure regulation, checking
      • Notes
      • Engine code ALH
      • Wastegate Bypass Regulator Valve N75 , checking
• 26 - Exhaust system, Emission controls
  • Exhaust system components, removing and installing
    • Exhaust system components, removing and installing
    • Front exhaust pipe and catalytic converter with attachments
    • Front exhaust pipe and catalytic converter with attachments for vehicles with all-wheel drive
    • Muffler with mountings
      • Notes
      • Installation position of double clamp
      • Installed location of mountings
      • Separation point on exhaust pipe
      • Installing muffler free of tension
    • Muffler with mounts for vehicles with all-wheel drive
  • Exhaust Gas Recirculation (EGR) system, overview
    • Exhaust Gas Recirculation (EGR) system, overview
    • Exhaust Gas Recirculation (EGR) system components, removing and installing
      • Engine code ALH
    • Vacuum hose connections, diagram
      • Engine code ALH
    • Exhaust Gas Recirculation (EGR) valve, checking
      • Notes
      • Engine code ALH
    • Exhaust Gas Recirculation (EGR), checking