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Go Back   TDIClub Forums > VW TDI Discussion Areas > TDI Power Enhancements

TDI Power Enhancements Discussions about increasing the power of your TDI engine. i.e. chips, injectors, powerboxes, clutches, etc. Handling, suspensions, wheels, type discussion should be put into the "Upgrades (non TDI Engine related)" forum. Non TDI vehicle related postings will be moved or removed. Please note the Performance Disclaimer.

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Old March 29th, 2016, 09:18   #1
arne487
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Default Just Another ALH Build

I suppose after working on it for over 8 years, it's about time I start a build thread for my 2003 Golf. Basically just a list of mods so I can keep track of them better. Questions or recommendations are welcome.

2.0L ALH
BHW Crank
BHW Pistons Ceramic Coated
PD150 Rosten Rods
17:1 CR
Ported ALH Head
Dual Valve Springs
Modified Valves
256/256 11mm Lift Camshaft
RyanP GTB2260VK and Heat Wrapped Tubular Manifold
4 Bar MAP Sensor
DRW 6-Speed w/ Upgraded Shift Forks
Wavetrac LSD
TDTuning
Giles 12mm IP Head on 11mm Body with 10mm Delivery Valves
DSSR 0.360 Nozzles
LCR PD Lift Pump
Derale 13225 Frame Rail Fuel Cooler
Ported PD150 Intake Manifold
Heat Wrapped PD150 TIP
2.5" FMIC
1.8T Pancake Pipe
R32 Snorkel/Airbox/MAF
ARP Head Studs
Whitbread Block Girdle
2 Micron CAT Fuel Filter
Air Filter Minder
DieselGeek FMJ Panzer
DieselGeek Oil Bypass Filter
205 F Thermostat
3” Downpipe
AeroTurbine 3030XL Resonator
Ventectomy
BFI Stage 2 Dogbone
ClutchMasters Dual Disc FX600
Lightweight Steel Flywheel
Euro Switch/Rear Fog
Joey-Modded R32 Headlights/Fogs in Glass
McNally Boost/EGT Gauge
VDO Fuel Press/Oil Press/Oil Temp Gauges
Alientech Window Module
Mini Antenna
Polo Rear Wiper
Mudflaps
Roof Rack
Hitch/Bike Rack
Conti ExtremeContact DW 225/55/16
Cover Mod
Alpine iDA-X100
Bilstein TC Sports
TT LCA Bushings
BFI RSB
FrostHeater
GLI Seats
Audi S3 Shift Knob w/ Red Stitching
Leather 3-Spoke GTI Steering Wheel
LED Trunk Lighting
OSB Reinforced Trunk Floor
Rear Bumper Sill Protector
Monster Mats
Cobra XRS 9845
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Last edited by arne487; September 25th, 2016 at 20:12.
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Old March 29th, 2016, 10:32   #2
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Gonna follow it. Mine's damn similar to this.
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Old March 29th, 2016, 18:12   #3
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Pics or it didn't happen (jk. just want to see some pics)
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Old March 30th, 2016, 20:41   #4
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Titan 502's?
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Old March 31st, 2016, 07:06   #5
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Quote:
Originally Posted by gloaming View Post
Pics or it didn't happen (jk. just want to see some pics)
Yeah, I've never been very good at taking pictures of a job unless I have an issue I need help troubleshooting. I'll see what I can find. There's at least one in this saga from a while back. http://forums.tdiclub.com/showthread.php?t=390152

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Originally Posted by Kevinski4 View Post
Titan 502's?
Yeah, it's a long story. These originally belonged to RyanP for his personal car. He decided not to use them over the R520s that he already had because they flowed too much. Ryan is one of the few vendors that I've never had any problems or concerns with and I trust and respect him quite a bit. When I bought these from him, they were already mounted and balanced. His claim was that they were from a very early batch of the Titans and had higher flow than R520 nozzles. I have no reason to doubt that. I am, however, saving up for some big DSS nozzles since, even with the modified 12mm pump, I think these are limiting me a bit.
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Hers: '10 TDI Cup Jetta - Just a skid plate and a Frostheater. She won't let me touch it.
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Old March 31st, 2016, 09:26   #6
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Titan 502, looking for a slight increase over stock performance?

That's a 120-130hp nozzle... I have the flow data on them, so it's not even a debate.
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Old March 31st, 2016, 10:04   #7
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Quote:
Originally Posted by Drivbiwire View Post
Titan 502, looking for a slight increase over stock performance?

That's a 120-130hp nozzle... I have the flow data on them, so it's not even a debate.
I disagree based on my personal experience. Can we leave the trolling to another thread, please?
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2004 Passat Wagon 1.8T 4-Motion 5-Speed
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Old March 31st, 2016, 10:24   #8
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I guess the definitive thing that will put any doubts about the nozzles to bed are dyno results.

From where are you getting the camshaft?
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Old March 31st, 2016, 11:05   #9
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Quote:
Originally Posted by TDIMeister View Post
From where are you getting the camshaft?
I got it through TDIinTexas, but I'm fairly certain that it's originally from Kyle. You know... the one bearing your name without consent...

For the record, everything in the original post is already complete (and has been for quite some time) so this is all thoroughly tested. Fastest "120 HP" TDI I've ever driven.
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Old March 31st, 2016, 11:14   #10
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All hatchets have been buried. Interested to know how you're liking it.
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Old March 31st, 2016, 15:26   #11
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I made so many changes at the same time, it's hard to separate the camshaft from the rest of the differences. I can say it keeps pulling crazy hard from 2400 RPM to 6000 RPM, so I assume flow is great. EGTs are nice and low. It sounds like a Harley and Mack truck had a lovechild. Pretty much no power to speak of below 2000 RPM but, like I said, so many variables it's hard to tie it to one thing.
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2004 Passat Wagon 1.8T 4-Motion 5-Speed
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Old April 5th, 2016, 17:00   #12
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Installed a fuel cooler today to keep the pump happy now that summer is on the way. Front mounted a 24" frame rail cooler under my intercooler.
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2004 Passat Wagon 1.8T 4-Motion 5-Speed
Hers: '10 TDI Cup Jetta - Just a skid plate and a Frostheater. She won't let me touch it.
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Old September 23rd, 2016, 21:24   #13
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Good news: My new DSSR nozzles are mounted and in the mail back from Giles.
Bad news: My clutch went out this morning, so time to go shopping.
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2004 Passat Wagon 1.8T 4-Motion 5-Speed
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Old September 27th, 2016, 05:57   #14
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Quote:
Originally Posted by arne487 View Post
Bad news: My clutch went out this morning, so time to go shopping.
What are you looking at? I am still searching for a clutch for mine.
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Old September 27th, 2016, 17:43   #15
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Thats a lot of candy!
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