BHW/ALH VE Hybrid...

jmodge

Veteran Member
Joined
Jun 18, 2015
Location
Greenville, MI
TDI
2001 alh Jetta, RC2 5speed daily commuter and 2000 alh Jetta 5spd swap, 2" lift, hitch, stage 3 TDtuning w/502's backroad cruiser
I just looked an an ALH I have on a stand. The water pump clocks differently, not sure about the size, but I bet IBW could tell you. The upper roller is in the accessory and pump bracket. Idler is in the head, and the lower roller is, if you follow a horizontal plane, within the bottom of the water pump bore away from the plug
 

jmodge

Veteran Member
Joined
Jun 18, 2015
Location
Greenville, MI
TDI
2001 alh Jetta, RC2 5speed daily commuter and 2000 alh Jetta 5spd swap, 2" lift, hitch, stage 3 TDtuning w/502's backroad cruiser
A little higher than that roller it appears and smaller in diameter
 

jimbote

Certified Volkswagen Nut
Joined
Jul 10, 2006
Location
spiral arm, milky way (aka central NC)
TDI
Tacoma 4x4 converted to TDI
Wow, thanks for all the observations, advice and the cjaa picture. I'm not discouraged yet, I welcome the challenge, sounds like fun ! I'll call yards Monday to get prices on the local cjaa core and used bhw pistons.
Ross

looking at the pic in this ^^ post you'll have to drill/tap both lower idle roller holes. It does appear that an ALH front seal holder will bolt right in. You can the chamfer WP hole by carefully sanding with a drum attachment, as long as the bore matches that of an ALH.
 

jimbote

Certified Volkswagen Nut
Joined
Jul 10, 2006
Location
spiral arm, milky way (aka central NC)
TDI
Tacoma 4x4 converted to TDI
I just looked an an ALH I have on a stand. The water pump clocks differently, not sure about the size, but I bet IBW could tell you. The upper roller is in the accessory and pump bracket. Idler is in the head, and the lower roller is, if you follow a horizontal plane, within the bottom of the water pump bore away from the plug
you're right, bolt clocking is different, plus the cjaa water pump hole looks HUGE compared to the ALH pump bore and it appears to protrude much farther out than the ALH.
 

Ross

Member
Joined
Feb 18, 2017
Location
Maine
TDI
01 Beetle ALH 5speed

looking at the pic in this ^^ post you'll have to drill/tap both lower idle roller holes. It does appear that an ALH front seal holder will bolt right in. You can the chamfer WP hole by carefully sanding with a drum attachment, as long as the bore matches that of an ALH.
Great, this all sounds very encouraging. Thanks so much Jim. By the way I have a 97 Tacoma Parts truck in the woods if you need anything. It's a standard cab 2wd 5 speed.
Ross Converse
 

jimbote

Certified Volkswagen Nut
Joined
Jul 10, 2006
Location
spiral arm, milky way (aka central NC)
TDI
Tacoma 4x4 converted to TDI
Great, this all sounds very encouraging. Thanks so much Jim. By the way I have a 97 Tacoma Parts truck in the woods if you need anything. It's a standard cab 2wd 5 speed.
Ross Converse
i think you need to read my posts after that...does not look like the cjaa will work at all for a VE setup.
 

Ross

Member
Joined
Feb 18, 2017
Location
Maine
TDI
01 Beetle ALH 5speed
i think you need to read my posts after that...does not look like the cjaa will work at all for a VE setup.
Okay, I've read through your posts and I admit I'm a bit confused now, I'm sure this is obvious but I don't have any experience with this motor. Could you summarize for me the biggest problems you see that would have to be overcome regarding the front of the motor. I understood about the water pumps being different.
 

jimbote

Certified Volkswagen Nut
Joined
Jul 10, 2006
Location
spiral arm, milky way (aka central NC)
TDI
Tacoma 4x4 converted to TDI
Okay, I've read through your posts and I admit I'm a bit confused now, I'm sure this is obvious but I don't have any experience with this motor. Could you summarize for me the biggest problems you see that would have to be overcome regarding the front of the motor. I understood about the water pumps being different.
looking at the front of the two blocks the cjaa will NOT work as a VE hybrid. Read my previous post about the water pump.
 

Ross

Member
Joined
Feb 18, 2017
Location
Maine
TDI
01 Beetle ALH 5speed
looking at the front of the two blocks the cjaa will NOT work as a VE hybrid. Read my previous post about the water pump.
Okay thanks for your time and expertise Jim, I'll continue looking for a bhw that I can afford. This is the safe way to go since you've worked it all out so thoroughly.
Have a good weekend,
Ross
 

jimbote

Certified Volkswagen Nut
Joined
Jul 10, 2006
Location
spiral arm, milky way (aka central NC)
TDI
Tacoma 4x4 converted to TDI
two more closeups, one of an ALH and one of a cjaa. They don't look terribly different from these angles. Another difference of note is no machined hole for the hard metal pipe. There is a nipple toward the rear of the block that may be for a heater hose. Screenshot_20201024-205738_eBay.jpgnScreenshot_20201024-205908_Chrome.jpg
 

Ross

Member
Joined
Feb 18, 2017
Location
Maine
TDI
01 Beetle ALH 5speed
a couple of things i would make sure of first. Water pump bore and impeller depth. clocking looks the same. I'm sure you can drill the cjaa for the two rollers.
Thanks for the pictures. Maybe wishful thinking but it sounds like you're still leaving open the idea this might work. Did you notice that I'm going mtdi so I don't need the reluctor or crankshaft sensor?
 

Ross

Member
Joined
Feb 18, 2017
Location
Maine
TDI
01 Beetle ALH 5speed
Thanks for the pictures. Maybe wishful thinking but it sounds like you're still leaving open the idea this might work. Did you notice that I'm going mtdi so I don't need the reluctor or crankshaft sensor?
I was also thinking if the blocks water pump bore is bigger than the alh water pump, possibly a sleeve could be machined to slip over the water pump to increase its diameter to match the block.
 

fjdiesel

Active member
Joined
Oct 2, 2017
Location
MN
TDI
76 fj40 w/02 ALH, 04 Jetta BEW
sweet! i'll be building another bhw/alh hybrid in the not to distant future and i'll amend this thread with new tdiclub hosted photos
Did you end up doing another BHW/ALH build?
 

Ross

Member
Joined
Feb 18, 2017
Location
Maine
TDI
01 Beetle ALH 5speed
a couple of things i would make sure of first. Water pump bore and impeller depth. clocking looks the same. I'm sure you can drill the cjaa for the two rollers.
Hi folks,
I decided to play it safe and not reinvent the wheel.
I just bought a supposedly good bhw short block from a Pennsylvania yard for $200. I'm going to build a hybrid with my good running alh and keep it electronic and forget the mtdi I'd originally planned.
Thanks for all your help. I feel I've made a wise choice.
Let the fun begin !
Ross
 

Ross

Member
Joined
Feb 18, 2017
Location
Maine
TDI
01 Beetle ALH 5speed
i have not, but i have all the parts including head studs, four or five ALH heads, and two BHW short blocks.
Hi Jim,
Thanks for sharing all your hard work and innovations with us, I never would have started my alh/bhw hybrid without your detailed instructions.
Ross
 
Top