Liseed
Veteran Member
After years of collecting parts for my 2003 VW Golf 2door, I finally got this thing together and fine tuned: All I can say is wow. Some of the below stuff I fabricated, some bought, some traded for. My goal was to build the long block for 250 WHP, and tune it for around 200 WHP with a Transmission with 1rs, 2nd, and 3rd modified for all out acceleration (aka stoplight runner), with 4th being a 'rural' driving gear and 5th a 'highway' gear matching peak torque rpm with my most common speed traveled on those roads (50 to 55 and 75 to 80 respectively). All this whilst still allowing for 50+ mpg (if I drive it 'normally'.) So mostly a daily driver with maximum stoplight to stoplight acceleration.
2003 VW ALH Motor;
GTB 1756 VK turbo on a Passat intake manifold, pinned and port matched exhaust inlet and outlet. 32psi with spikes into upper 30s.
HFLO-X Race Nozzles @ .280 (mostly smokless or blocks the sun, depending on which tune I am using)
11mm Injector pump rebuilt and modified for more timing supported by an in tank lift pump.
CAT 2 micron fuel filter.
Ported/polished head with dual valve springs, stage II camshaft with .020 additional lift, 3 angle valve seats, nitrided cam followers, line up pins for intake and exhaust manifolds installed, port matched to the both the exhaust and intake manifold.
PD 150 intake manifold pinned and port matched to the head.
R32 intake box (true 3 inch intake all the way to the turbo inlet).
Stock ALH MAF sensor installed into the 3" R32 MAF housing.
3" custom made turbo inlet pipe.
FMIC and 2.0" aluminum turbo piping where possible.
4 bar MAP sensor.
2.5 inch cat back exhaust.
Bored and decked.
Balanced rotating assembly.
Slightly lower compression over stock. (my stick out was near the upper limit for a one hole head gasket, so I used the next size up (2 hole MLS)).
Integrated Engineering forged rods.
Nural ASV style 80.0 mm bore pistons with Goetze rings.
ARP studs at the head, rods, and mains.
BRM oil pump gears.
Fluid harmonic dampener.
Vibra Technics motor and trans mounts.
Stage 5 custom Malone tune and separate RC6 custom tune.
ASV and EGR deleted.
Idle at 1050 rpms.
Easily redlines to 6000 RPMs.
O2J Transmission rebuilt with all new bearings and seals, assembled and modified from many sources:
South Bend stage 3 endurance clutch.
Peloquin LSD.
3.16 R&P.
Other:
OEM Aristo rims off an R32 with 235 45 18 Continental Extreme Contact DWS.
Impressions:
On a hard run, accelerates very fast to 80 to 95 mph in first, second, third gears. Fourth continues to pull very strongly with fifth also pulling strongly, but not like 4th, even up hills. Silky smooth idle, Silky smooth acceleration no vibration at all in the interior. Vibrates some (not too bad) at the stock 900 rpm setting, so I bumped the idle up to 1050, at 1050 there is no vibration at all in the interior. Very good daily driver, IMO, almost no lag at all, picks up nicely from 1200 rpms in any gear except 5th which will struggle just a little on steep hills below 1500 rpms, but above 1500 rpms, on steep hills, 5th picks up just fine. Even if you accelerate 'normally' by keeping boost at 15 psi or below, it still picks up and goes like my old 130hp stage 2 tune. That said, the real fireworks come in at 2200 RPMs to 5500 or so. Peak torque feels like it is at around 2300 rpms.
Acceleration is so smooth and stable when making a fast run, it is deceptive, you are suddenly at 85 or 90 mph at the end of 3rd gear without really realizing it. This car will get me in trouble, LOL.
MPG: If i drive it 'normally' I get around 54 mpg on long highway trips. Driving it with full on fun factor still gets around 40 mpg. Not bad, I would say!
2003 VW ALH Motor;
GTB 1756 VK turbo on a Passat intake manifold, pinned and port matched exhaust inlet and outlet. 32psi with spikes into upper 30s.
HFLO-X Race Nozzles @ .280 (mostly smokless or blocks the sun, depending on which tune I am using)
11mm Injector pump rebuilt and modified for more timing supported by an in tank lift pump.
CAT 2 micron fuel filter.
Ported/polished head with dual valve springs, stage II camshaft with .020 additional lift, 3 angle valve seats, nitrided cam followers, line up pins for intake and exhaust manifolds installed, port matched to the both the exhaust and intake manifold.
PD 150 intake manifold pinned and port matched to the head.
R32 intake box (true 3 inch intake all the way to the turbo inlet).
Stock ALH MAF sensor installed into the 3" R32 MAF housing.
3" custom made turbo inlet pipe.
FMIC and 2.0" aluminum turbo piping where possible.
4 bar MAP sensor.
2.5 inch cat back exhaust.
Bored and decked.
Balanced rotating assembly.
Slightly lower compression over stock. (my stick out was near the upper limit for a one hole head gasket, so I used the next size up (2 hole MLS)).
Integrated Engineering forged rods.
Nural ASV style 80.0 mm bore pistons with Goetze rings.
ARP studs at the head, rods, and mains.
BRM oil pump gears.
Fluid harmonic dampener.
Vibra Technics motor and trans mounts.
Stage 5 custom Malone tune and separate RC6 custom tune.
ASV and EGR deleted.
Idle at 1050 rpms.
Easily redlines to 6000 RPMs.
O2J Transmission rebuilt with all new bearings and seals, assembled and modified from many sources:
South Bend stage 3 endurance clutch.
Peloquin LSD.
3.16 R&P.
Other:
OEM Aristo rims off an R32 with 235 45 18 Continental Extreme Contact DWS.
Impressions:
On a hard run, accelerates very fast to 80 to 95 mph in first, second, third gears. Fourth continues to pull very strongly with fifth also pulling strongly, but not like 4th, even up hills. Silky smooth idle, Silky smooth acceleration no vibration at all in the interior. Vibrates some (not too bad) at the stock 900 rpm setting, so I bumped the idle up to 1050, at 1050 there is no vibration at all in the interior. Very good daily driver, IMO, almost no lag at all, picks up nicely from 1200 rpms in any gear except 5th which will struggle just a little on steep hills below 1500 rpms, but above 1500 rpms, on steep hills, 5th picks up just fine. Even if you accelerate 'normally' by keeping boost at 15 psi or below, it still picks up and goes like my old 130hp stage 2 tune. That said, the real fireworks come in at 2200 RPMs to 5500 or so. Peak torque feels like it is at around 2300 rpms.
Acceleration is so smooth and stable when making a fast run, it is deceptive, you are suddenly at 85 or 90 mph at the end of 3rd gear without really realizing it. This car will get me in trouble, LOL.
MPG: If i drive it 'normally' I get around 54 mpg on long highway trips. Driving it with full on fun factor still gets around 40 mpg. Not bad, I would say!
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