Where Can I Get Oversized TDI Pistons?

I have been searching for some oversized pistons for the ALH TDI engine. I will be rebuilding my 321k mile engine and if the pricing isnt too high i'd like to bore the block to an oversize and use new pistons and rings instead of the low mile shortblock i have for parts. Has anyone done an ALH rebuild with oversize parts?

Where are you located?

Passenger Performance may be able to get oversized TDI pistons for a fair price.

Utah, USA. you know, where diesel is unknown still.

Thats funny. Kerma is from Utah as are some other bigtime diesel folks.

Yep I sell oversize pistons, cna also sell them with the lip machined and ceramic coated, even with total seal rings. Shoot me an email info@passengerperformance.com and tell me what you are looking for.

Where in Utah? I would say we have a pretty strong TDI and diesel following in Utah. Don't believe it, attend "weekend on the edge" in ogden first part of Sept and you will see. Jump into the Mountain/Southwest forum we have a few G2Gs during the year.

Phil

I live in Orem Utah. I guess there are some diesel people in northern utah but i haven't seen any TDI enthusiasts around here. Quite a few full size truck people, most of whom are dumb and just blow black smoke everywhere.
Emailing you about the pistons...

Put in transporter 00-04 2.5tdi´s pistons. Works like original but little more fun and are a direct fit. Only 1.5mm oversize what gives you 1968cc / 2.0l tdi and you can get them almost everywhere at least here in europe.

Tell me more about these transporter pistons and where i can buy some. This idea sounds good to me. In the 1.9l TDI i believe there are two pistons and two pistons that are different.

Dareo, please update your profile with your location. Help us so that we can help you. It is frustrating to wonder where someone comes from so that appropriate information can be given. Yes, I know you stated your location in a post above, but do you want to do that for every thread?

I'll tell you why: what would you say if I tell you that you can get 81mm pistons (the same size as the T4 Transporter ones) without having to resort to sourcing them from Europe? The North American B5.5 Passat TDI is such the case. The difference between VE vs. PD injection systems apparently doesn't matter too much as far as the bowl geometry is concerned. And you get a desireable drop in compression ratio if you're going to tune the engine substantially from stock power levels. I don't know if the conrod small-ends are the same diameter, but the PD134 conrods should be substantially beefed up over the ALH ones.

dareo said:

Tell me more about these transporter pistons and where i can buy some. This idea sounds good to me. In the 1.9l TDI i believe there are two pistons and two pistons that are different.

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For 1.9 tdi you can go for 3 different types of pistons with 2 dif. bore diameter or you can go for R5 pistons which is in 2 diameters 81,01 and 81,51 with different compression height....

Go for oversized 81,51!!!!!

Has anybody done a 81.5mm bore TDI in the United States? I love the idea of an oversized TDI. I've got a new VNT17, bigger nozzles, ecu tune, and a GHL turboback exhaust to complement. How much would these pistons affect my compression ratio?

Still looking for some oversized pistons. Anybody know where i can get these?

LTR said:

Put in transporter 00-04 2.5tdi´s pistons. Works like original but little more fun and are a direct fit. Only 1.5mm oversize what gives you 1968cc / 2.0l tdi and you can get them almost everywhere at least here in europe.

Click to expand...

What engine codes are the ones that will fit the ALH connecting rods? Unfortunatly ETKA does't list the wrist pin size. The ALH uses 26x1.5 so the only 2.5L pistons that use that would be codes:

AHY
AXG
AYY
AJT late
ACV late
AYC late
AUF late

There is listings for different pistons for all the different engine codes - even differences between manual and automatic transmissions.

So assuming that the same size snap ring would result in the same size wrist pin, would it be safe to assume that the connecting rods would be correct as well?

The wheels are a-turning for my Golf Country project!

TDIMeister said:

I don't know if the conrod small-ends are the same diameter, but the PD134 conrods should be substantially beefed up over the ALH ones.

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On this subject, are the pd 150 con rods similar to the alh rods? Is the big end diameter the same, and are they the same length? This would be much easier than having a custom set made for my ALH project. Also what year is the B5.5 passat, so I can get a set of those pistons?

turbobuilder said:

On this subject, are the pd 150 con rods similar to the alh rods? Is the big end diameter the same, and are they the same length? This would be much easier than having a custom set made for my ALH project. Also what year is the B5.5 passat, so I can get a set of those pistons?

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IF you need tdi piston just tell me what diamter and I will do a custom new one with chamber design and compression ratios direct by your spec (price per set only pistons 860euro). About rods custom PD set is recomended to 600Nm, H type cost per set 780Euro.

That would be a great deal from StingrayRT compared to buying new OEM, especially if as he has said in the past he can supply 83+ mm pistons. You'd be the big dog for 4 cyl. TDI displacement.

Do it and let us know.

Edit: If any piston spec. is available just for the asking, why stop at 83mm? Ask for an 86mm set and the best chamber shape and compression ratio that will give 600 Nm. Best money you'll ever spend.

StingrayRT said:

IF you need tdi piston just tell me what diamter and I will do a custom new one with chamber design and compression ratios direct by your spec (price per set only pistons 860euro). About rods custom PD set is recomended to 600Nm, H type cost per set 780Euro.

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TDIMeister said:

That would be a great deal from StingrayRT compared to buying new OEM, especially if as he has said in the past he can supply 83+ mm pistons. You'd be the big dog for 4 cyl. TDI displacement.

Do it and let us know.

Edit: If any piston spec. is available just for the asking, why stop at 83mm? Ask for an 86mm set and the best chamber shape and compression ratio that will give 600 Nm. Best money you'll ever spend.

Click to expand...

Because it must use a stock piston rings the tdi one is different type I not sure. I use the rings from stock tdi pistons.....

86mm??? You are kiddning me?? Maximum is 83.5mm any bigger cannot be done...

So your using a stock size piston ring on an oversized piston?

TDIMEISTER.........that wasn't a leading taken for granted question was it........."86mm"....................at 83.5mm could you not custom make or have the rings made also via someone STingrayRT!!.

KROUT said:

So your using a stock size piston ring on an oversized piston?

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I use different diesel type rings.....I´m not sure to using a gasoline turbo rings at diesel....thus I use a stock oversized from different types...

Got ya.

Hi, have a look at www.all4tdi.de 2.1L stroker kit available...
good luck

i always thought that useing a stroker kit would further hurt the rpm... because the engine has soo much stroke and not enough bore (over square or undersquare... not sure which one) wouldn't boring it give you mor hp and tq... while allowing you to use mor of the upper rpm

Following up on this old thread instead of starting a new one.

I need to give my AHU engine an overhaul. An instead of just changing all the bearings, gasket, piston rings etc. I might as well change the pistons. So why not bore it bigger

The pistons from the T5 is a plug in and I can get them in 81 mm for a good price here in Europe.

This give me 2 questions:

1. What year/motor codes am I aiming for since they do not all fit? It have been asked before in this thread without an answer besides year 00-04. But it is not that simple since it seems like the T5 first came around 03 and if I use the year like 00, 01 or 02 they are called T4, please see here:
http://www.ebay.de/itm/Kolben-pisto...352580?hash=item2367ae9f04:g:imoAAOSw2GlXGV4n

http://www.ebay.de/itm/Neuer-Kolben...774010?hash=item1eac3e29fa:g:wucAAOSwuxFYzUS7

2. What about head gasket?!? The standard one for the AHU/1Z engines are for 80 mm, does any other fit? And what about custom made ones, this sounds expensive

The head gasket is the issue - I don't believe there is a gasket available for a bore that large. 81mm pistons will hit the stock sized gasket.

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A little more study on the head gasket reviles that the G60 seems to be a fit.

The bore here is 82 mm and the thickness of the gasket is 1.50 mm - similar to the 2 holes AHU gasket, this one is 1.53 mm and the 3 holes gasket 1.61 mm.
http://www.ebay.de/itm/Metall-Zylin...547731&hash=item3f171c38af:g:t-kAAOSwXXxZVpcp

I found some good details so I could compare the size of the pistons. There difference between the T4 and T5 pistons is the well depth and the depth of the valve carving. If I use the G60 head gasket and T4 pistons the spacing to the valves will be reduced by 0.06 mm and with the T5 pistons reduced by 0.01 mm. So this will work in both cases for sure.

But what worries me is the squish and compression ratio... This squish is reduced by 0.31 mm for both T4 and T5, does anyone know the original squish for an AHU engine? Standard crank, pistons and conrods?
(A roughly calculation based on the well size, valve carving, bore/stroke and the default compression ratio of 19.5:1 is giving me a number around 1.6 mm)

For the compression ratio, taking the well depth and valve carving into consideration a roughly calculation give between 22.5:1 and 23:1 - this is not going to work :-(

So I need the number confirmed so I can do some actual calculations: what is the squish and do anyone know the actual volume above the piston at TDC? and that would be the original one where the bore is 79.50 mm

Passat 2.0L head gasket is what I used when I punched out the BEW/ALH to 81mm, plus you can get bigger than 81mm. Not sure if that works in your application.

I had my block bored for bhw 2.0 pistons. Factory pistons out of a 04-05 Passat tdi. Also using the bhw factory 2 hole head gasket. I upgraded to rosten rods too with arps. I've got most of my info and parts sourcing from darkside. They really know their stuff.

The PD gasket works if you are starting with an ALH, however the AHU/1Z have different oil and coolant passages.

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