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TDI Conversions Discussions on converting non TDIs into TDIS. More general items can be answered better in other sections. This is ideal for issues that don't have an overlap and are very special to swaping engines.

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Old March 30th, 2012, 14:25   #1
jhax
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Default jhax's Built ALH into a MK2 Golf thread

Hello Everyone,

Well I have been doing some research for a few months and I'm ready to post the first few pictures and information on my new project. I'll be building up a 250+ HP ALH and throwing it (putting that lightly) into a MK2 golf. Any information and input would be appreciated and encouraged. I know i can learn a lot from some of your more experienced forum guys....Enough blabber, bring on the information and some pictures!!!

BOTTOM END
CRANK: Stock ALH crank can be used
PISTONS & RODS: ASV, Integrated Engineering ($775)
Hardware: ARP Mahle http://www.autohausaz.com/search/pro...r=034105701007

OIL PAN: http://www.metalmanparts.com/product...&categoryId=74
CRANK GIRDLE: http://forums.tdiclub.com/showthread.php?t=327439

TOP END
CAM: Colt stage 2 (almost OEM adds 10whp) (http://www.kermatdi.com/servlet/-str...Stage-2/Detail)
LIFTERS: INA PD black lifters (http://www.idparts.com/catalog/produ...oducts_id=2670)
GASKETS: 3 notch(thickness) head gasket
HEAD: port and polish
VALVE SPRINGS: double valesprings (1 small 1 large) is needed

TRANS & COMPONENTS
TRANSMISSION: I had my 5 spd tranny beefed up at Advanced Automotion (Scott DeWitt) in Corpus Christy, TX. All the gears and input shaft are cryo-treated and surface strengthened. (Joe TDI), Pelonquin Limited Slip Differential (http://thescirocco.com/peloquin.html)
CLUTCH: I use DC stage 4 from boraparts.com (http://shopping.boraparts.com/produc...roducts_id=227)
PEDAL CLUSTER: B4 Passat cluster with MK4 DBW accel pedal welded on
SHIFT CABLES: MK3 shifter cables
SHIFTER: MK3 (O2J) Shifter


ELECTRONICS:
ECU: MAF DELETE, 3-4 BAR MAP upgrade, chip
WIRING: 1998-1999.5 ALH wiring harness as they do not have an immobilzer. NON ABS
VCDS (vagcom) you can change the coding to switch between daily and drag program for instance
OBD2 Ports
OPTIONS: MK3 (CE2) sensors???


FUEL:
Injection Pump: 11mm IP
LIFT PUMP: PD in-tank lift pump (http://www.idparts.com/catalog/produ...roducts_id=911, http://idparts.com/catalog/product_i...roducts_id=585)
FUEL TANK: MK3 tdi fuel tank
FUEL LINES: custom fuel lines
FUEL FILTER ASSEMBLY: MK3 assembly
FUEL SENDER: MK3 fuel assembly
Nozzles: race520 nozzles or even bigger like nicktane makes (Bosio Race 520 Stage II)


AIRFLOW:
AIRBOX: (r32 or VR6), bigger intake pipe (Cone filter?)
INTERCOOLER: big intercooler pipes w/big front mount intercooler
INTAKE MANI: bigger intake manifold (Custom Aluminum)
EXHAUST: open 3" exhaust (Custom), V-band
TURBO: gtb2056vk or gtb2260vk (if these are used talk to Rub87 for mani) turbo vnt 17


Basic engine components, head, crank, block and other misc brackets and such.


ASV code oversize pistons (80mm) and Integrated Engineering rods. Thank you myke_w





Looks like a good fit to me. ALH rods with the ASV pistons.

EDIT: cant seem to post pictures from flickr onto the forum. I go to the pictures individually, click on the Share link where it drops down to a box that says (Here's a link to this photo. Just copy and paste!) and the link is given, I copy the link and click the add image in the forum edit bar and paste the link. so here is the flickr photo stream. (http://www.flickr.com/photos/78594984@N08/)

Let's start with comments and suggestions.

Last edited by jhax; March 31st, 2012 at 13:30. Reason: deleted hansautoparts link
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Old March 30th, 2012, 14:33   #2
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I didn't even read more than a couple words before I scanned it and this popped out immediately
[url]http://www.hansautoparts.com/TDIInjectorPumpAutoALH.aspx[/url

DO NOT PURCHASE ANYTHING FROM HIM! IT IS GARBAGE AND WILL WRECK YOUR ENGINE.
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Old March 30th, 2012, 15:28   #3
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Quote:
Originally Posted by JFettig View Post
I didn't even read more than a couple words before I scanned it and this popped out immediately
[url]http://www.hansautoparts.com/TDIInjectorPumpAutoALH.aspx[/url

DO NOT PURCHASE ANYTHING FROM HIM! IT IS GARBAGE AND WILL WRECK YOUR ENGINE.
X2!!! This project sounds too cool to waste it with a bunk IP!
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Old March 30th, 2012, 16:31   #4
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You also need to upgrade a few items on your list to get 250hp out of an ALH. Prob injection pump for sure and nozzles.
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Old March 31st, 2012, 03:26   #5
jhax
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Thank you guys for the info. And Nash, hence the 11mm IP and the race 520 nozzles. I have heard about the 12mm pump but I havent heard good news about it. Also, any info on how to post pictures up?

Last edited by jhax; March 31st, 2012 at 03:27. Reason: Add to post
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Old March 31st, 2012, 12:05   #6
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The parts you have listed are good for 175-180hp.
For a mk2 that is more than enough whp.

Update us with some pics.

Thanks.
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Old March 31st, 2012, 12:50   #7
jhax
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still cant figure out how to add pictures so they dont show up as broken links. i resized them to make them smaller and they still wont work
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Old March 31st, 2012, 13:12   #8
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HOw many sites does this guy have Hansautoparts.com NEVER NEVER NEVER BUY ANY OF HIS CRAP..OR OTHERWISE KNOW AS THIS RIP OFF...
Rothenbacher Engineering
5005 Smith Farm Rd.
Matthews, NC 28104
Phone Number: 1.704.684.1235
ANYTHING that comes from Rothenbacher Engineering is total JUNK run far far away and never look back
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Old March 31st, 2012, 13:14   #9
jhax
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alright, thank you ducky. it has been established, this guy produces terrible products.
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Old March 31st, 2012, 13:20   #10
jhax
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Old March 31st, 2012, 13:21   #11
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Alright figured it out!!! Hold on kids here we go!!!
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Old April 1st, 2012, 08:04   #12
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figured it out eh?
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Old April 1st, 2012, 12:26   #13
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yes sir, so on with the suggestions!
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Old April 3rd, 2012, 20:34   #14
jhax
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Well not much of an update but it's something. Spent the evening cleaning off some of the miscellaneous stuff that came with the engine.


Also, I was talking with a Vortex member who previously did a MK2 ALH swap and when I asked him about wiring he said this:

"The mk2 fusebox has a harness for the Mk2 ECU. It's just a matter of splicing switched/constant/ground between the two old fusebox harnesses and the new ECU plug.

In addition to the switched/constant/ground on the ECU, you will also have the drive by wire pedal to wire (its like 6 wires or something, pretty easy). If you want cruise control, then you have more to deal with..."

Any response to this?

Last edited by jhax; April 3rd, 2012 at 20:36.
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Old April 12th, 2012, 14:16   #15
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If you want cruise control you'll obviously need to wire in the stalk but also the clutch cancel and brake cancel switches on the pedals.
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