The ALH Deluxe Kit is
for people who want maximum peace of mind.
Everything you need for the ALH VW timing belt replacement! These kits fit all
TDI ALH cars and include all normally replaced parts on the timing belt side of
the engine. The reason we call these kits 100K kits is that they include every
new part related to the timing belt including the upgraded 62mm bearing large idler
roller that was introduced in 2003. In 2003, VW gave the ALH TDI a rated 100K
timing belt change interval which was 20,000 miles higher than for 2002. The
large bearing idler roller was the difference. Year model 2002 and earlier cars
used a 47mm bearing in the large idler roller. This kit updates older cars that
used the older 40k and 60K mile belts and tensioners to allow the same 2003
Jetta TDI timing belt replacement interval of 100k miles.
This kit includes also includes a very handy Water Pump Removal Kit as a
complimentary gift. This exclusive Dieselgeek removal kit makes the water pump
change much easier! The complimentary Water Pump Removal Kit is only available
with purchase of the Deluxe Timing Belt Kit. Instructions for using the water
pump removal kit are included in the timing belt kit's box and are also printed
on this page under the extractor set's heading. This kit does not include the
ALH Metalnerd timing belt tools from available separately. (see below)
Kit includes (click
underlined part name for picture or see YouTube unboxing video below):
Timing Belt: 038 109 119M from Gates, the only OE supplier. This
super tough Aramid reinforced timing belt was made in the United Kingdom on the
same machines that make the OE printed belts and are made to the exact same
standards as the OE belts. The materials are also exactly the same. They differ
from OE only in that they are not printed with the OE part number.
Litens Belt Tensioner: 038 109 243N made by Litens, the only OE
supplier. The ALH Litens tensioner was made in Canada on the same machines that
make the OE branded tensioners and are made to the exact same standards as the
OE branded tensioners. The materials and specs are exactly the same. They are
differentiated from the OE branded tensioners only by the color of the plating
and they are not stamped with the OE part number. The same part for less money!
pump: A proven favorite with many thousands in TDI service. Hepu
pumps have a steel impeller that will never break or separate from the shaft
like OE plastic impeller water pumps. A finish machined impeller casting makes
for great coolant flow.
Exclusive Dieselgeek.com Water Pump Removal Kit: Oftentimes the water
pumps on the new style TDI engines are hard to remove from the engine block due
to a tight fit, corrosion, and water pump O-rings that like to stick to the
engine block. We here at dieselgeek.com have had a screw set custom-made
that make the extraction of these difficult water pumps MUCH easier. To use the
water pump removal screws, first simply remove the three black 7mm screws
holding the water pump to the engine block with a 10mm socket and ratchet.
Next, for best results, apply a generous amount of grease the threads of each
of the three water pump removal screws. (It doesn’t matter what kind of grease
you use and the screws will usually work without grease.) Lastly, using an 11mm
or 7/16” inch socket, tighten the three screws evenly into the three water pump
mounting holes. The water pump will be conveniently and easily pushed out of
the engine block by the screws. The threads of the engine block WILL NOT be
damaged in any way!
These rollers are made by INA, the only Original Equipment supplier. Ina
timing belt kit includes all three idler rollers with the large roller being
equipped with a 62mm bearing that came standard on 2003 cars. All
ALH-equipped cars built from 1998 through 2002 had big diameter rollers with
the smaller 47mm bearing. Kit also includes one OE stretch bolt from VW for the
large roller since this roller blocks access to water pump and must be loosened
and removed to replace the water pump. You must replace this stretch bolt every
time it is loosened. This bolt should be torqued to 30 lb. /ft PLUS
Belt: 038 903 137J Gates Green Stripe belt, the only
serpentine belt designed for 100K mile service! Made in the U.S.A.--A
Dieselgeek Exclusive. Click here
for a Gates serpentine belt routing diagram.
32x47x10mm DPH brand German cam seal of the spring type preferred by many
highly experienced TDI timing belt installers (Included in case your seal is
Hint: You should lubricate the cam seal with motor
oil before you install it. Also, you should tape over the camshaft keyway with
electrical tape before you install the cam seal to keep the lips of the seal
from being cut or rolling over during install. Also we recommend removing any
surface rust (with steel wool) from the tapered cam hub before installing the
cam seal to prevent seal damage.
NOTE: Due to the wide
variation of install quality, there is absolutely no warranty on cam seals
including any incidental damages or extra labor incurred to replace a leaking
Vacuum pump seal: This seal is Original Equipment from the dealer.
It will seep unless replaced.
All four motor mount stretch bolts:
Original Equipment from
the VW dealer. These stretch bolts are the latest part numbers from
VW/Audi and the shorter ones are now even stronger than the earlier ones with
blue plastic on the threads! (Grade 10.9) These bolts are coated with
Cerachrome which helps prevents galvanic corrosion. You MUST replace these
every time they are loosened. The large ones are torqued to 74 lb. /ft and the
smaller ones are torqued to 30 lb. /ft PLUS ¼ turn.
All three horizontal motor mount
bolts: Original Equipment from
the VW dealer. Sometimes reused bolts break so we supply new ones for added
All four grade 12.9 zinc-plated crankshaft
harmonic balancer bolts to replace those soft stock bolts! These bolts are provided as
convenience items in case you strip out the Allen socket holes of your stock
bolts. In rare cases these bolts may not work on some late 2003 engines as they
will be too long.
Three valve cover Allen
bolts with washers in case you damage a few
on removal. They are provided as a convenience item in case you strip out the
5mm Allen socket holes of your stock bolts.
Three Phillips drive belly pan screws for the lower
engine covers are included since most people are missing some. Really
convenient items to have on hand!