jhax's Built ALH into a MK2 Golf thread

jhax

Veteran Member
Joined
Jan 24, 2012
Location
Golden, CO
TDI
96 Passat B4V, ALH engine out of a 2002 Jetta, some IE Rods and ASV Pistons. Nothing drivable yet though
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/product.aspx?sid=f24gol55vvzmy545msbzlivn&partnumber=034105701007

OIL PAN: http://www.metalmanparts.com/product.sc?productId=80&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/-strse-702/Colt-Cams-Stage-2/Detail)
LIFTERS: INA PD black lifters (http://www.idparts.com/catalog/product_info.php?products_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/product_info.php?cPath=21_26_33_51&products_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/product_info.php?products_id=911, http://idparts.com/catalog/product_info.php?products_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.
 
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JFettig

Vendor
Joined
Aug 18, 2010
Location
Blaine, MN
TDI
B5 Passat, 2010 Jetta
I didn't even read more than a couple words before I scanned it and this popped out immediately
http://www.hansautoparts.com/TDIInj...IM! IT IS GARBAGE AND WILL WRECK YOUR ENGINE.
 

Nash_TDI

Veteran Member -TDIClub Enthusiast
Joined
Sep 3, 2002
Location
Louisville, ky
TDI
2000 Silver Jetta TDI
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.
 

jhax

Veteran Member
Joined
Jan 24, 2012
Location
Golden, CO
TDI
96 Passat B4V, ALH engine out of a 2002 Jetta, some IE Rods and ASV Pistons. Nothing drivable yet though
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?
 
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Puebla

Veteran Member
Joined
Dec 12, 2003
Location
NATIONAL CITY, CA.
TDI
MK4 TDI GT25, PP520'S, FMIC, STAGE 5 SOFTWARE
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.
 

jhax

Veteran Member
Joined
Jan 24, 2012
Location
Golden, CO
TDI
96 Passat B4V, ALH engine out of a 2002 Jetta, some IE Rods and ASV Pistons. Nothing drivable yet though
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
 

Dieselducky

Veteran Member
Joined
Oct 13, 2011
Location
Dunnville
TDI
88 Jetta Diesel - 2000 Jetta TDI - 04 BMW M3 - 06 Kia Rio - F350 Superduty - 87 Buick GNX - Mobile Cranes
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
 

jhax

Veteran Member
Joined
Jan 24, 2012
Location
Golden, CO
TDI
96 Passat B4V, ALH engine out of a 2002 Jetta, some IE Rods and ASV Pistons. Nothing drivable yet though
alright, thank you ducky. it has been established, this guy produces terrible products.
 

jhax

Veteran Member
Joined
Jan 24, 2012
Location
Golden, CO
TDI
96 Passat B4V, ALH engine out of a 2002 Jetta, some IE Rods and ASV Pistons. Nothing drivable yet though

jhax

Veteran Member
Joined
Jan 24, 2012
Location
Golden, CO
TDI
96 Passat B4V, ALH engine out of a 2002 Jetta, some IE Rods and ASV Pistons. Nothing drivable yet though
Alright figured it out!!! Hold on kids here we go!!!
 

jhax

Veteran Member
Joined
Jan 24, 2012
Location
Golden, CO
TDI
96 Passat B4V, ALH engine out of a 2002 Jetta, some IE Rods and ASV Pistons. Nothing drivable yet though
yes sir, so on with the suggestions!
 

jhax

Veteran Member
Joined
Jan 24, 2012
Location
Golden, CO
TDI
96 Passat B4V, ALH engine out of a 2002 Jetta, some IE Rods and ASV Pistons. Nothing drivable yet though
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?
 
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greengeeker

Vendor
Joined
Feb 8, 2006
Location
Cambridge, MN
TDI
2002 Jetta GLS
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.
 

FredS

Veteran Member
Joined
Nov 25, 2009
Location
AZ
TDI
01 Golf GL 5spd, 00 NB 5spd, 94 Toyota-01ALH
Have you already sorted out the emissions side of doing this conversion in Maricopa County with ADEQ?
 

jhax

Veteran Member
Joined
Jan 24, 2012
Location
Golden, CO
TDI
96 Passat B4V, ALH engine out of a 2002 Jetta, some IE Rods and ASV Pistons. Nothing drivable yet though
Green, thank you for that info, didnt even know such switches existed. i assume if i happen to find a shell with cruise control i shouldnt have a problem.

Fred, lucky for this guy, I have an old address up in Prescott, AZ (Yavapai County) which i will be registering the car to which means NO EMISSIONS FOR MEE!!!

Oh and another snag i have come to is the cluster and wiring. I am planning on using a pre-2000 ecu and harness and would like to run a mk3 cluster so i dont have to worry about messing with the cluster housing to accommodate the MK4 cluster. I have done some searching on this subject and have not found much (though i still need to do more). I have learned that the mk4s used various signals through the can bus which obviously was not used in the mk3s. Any suggestions?
 
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jhax

Veteran Member
Joined
Jan 24, 2012
Location
Golden, CO
TDI
96 Passat B4V, ALH engine out of a 2002 Jetta, some IE Rods and ASV Pistons. Nothing drivable yet though
my thoughts exactly
 

jhax

Veteran Member
Joined
Jan 24, 2012
Location
Golden, CO
TDI
96 Passat B4V, ALH engine out of a 2002 Jetta, some IE Rods and ASV Pistons. Nothing drivable yet though
alright ladies and gentlemen i have another question. So i have been working on wiring diagrams, drawing a pin out diagram using the link G60ing put up here (http://pics.tdiclub.com/data/517/DZSL_SLC_Wiring_4_Engine.pdf). This diagram is for an ALH engine and uses an 80pin ECU. From what I have been reading (and it has been a lot of reading), the 80pin ECU is from an AHU and the ALH uses the 121 pin ECU according to post 14 in this thread http://forums.tdiclub.com/showthread.php?t=227196 so what do i need to be looking for here? I need to buy an 80 pin ALH ECU (pre-2000?) with no IMMO. I just dont want to end up doing all of this diagram work for nothing.

Thanks All,

Justin
 

jhax

Veteran Member
Joined
Jan 24, 2012
Location
Golden, CO
TDI
96 Passat B4V, ALH engine out of a 2002 Jetta, some IE Rods and ASV Pistons. Nothing drivable yet though
got it figured out
 

jhax

Veteran Member
Joined
Jan 24, 2012
Location
Golden, CO
TDI
96 Passat B4V, ALH engine out of a 2002 Jetta, some IE Rods and ASV Pistons. Nothing drivable yet though
Alright everyone, i need to draw up one more connector (VSS) in my diagram and i will throw it in a PDF and post it on here. It has taken me weeks to draw this and it had better be right. The diagram I am posting up is from a pre2000 non IMMO Jetta/Golf wiring diagram. I need to make a new one for the wiring harness and ECU I am going to be purchasing (1998-1999 Beetle). Am I correct in assuming that I can use a Jetta instrument cluster with a Beetle harness and ECU? Both use the Green and Blue 32 pin plugs.
 

jhax

Veteran Member
Joined
Jan 24, 2012
Location
Golden, CO
TDI
96 Passat B4V, ALH engine out of a 2002 Jetta, some IE Rods and ASV Pistons. Nothing drivable yet though
link edited, let me know if it works
 

G60ING

Top Post Dawg
Joined
Aug 5, 2001
Location
Alexandria, VA
TDI
No TDIs Currently, I have an R36 Corrado. I've had an ALH Corrado swap, AHU Corrado swap and 2003 TDI Jetta

jhax

Veteran Member
Joined
Jan 24, 2012
Location
Golden, CO
TDI
96 Passat B4V, ALH engine out of a 2002 Jetta, some IE Rods and ASV Pistons. Nothing drivable yet though
You wanna donate $800 for my bottom end? At this rate im throwing $100 every two weeks into my account for my crank girdle, hardware and boring the cylinders. I am tossing around the idea of lightening the crank. But im not sure if its necessary.
 

jhax

Veteran Member
Joined
Jan 24, 2012
Location
Golden, CO
TDI
96 Passat B4V, ALH engine out of a 2002 Jetta, some IE Rods and ASV Pistons. Nothing drivable yet though
Alright everyone, I have decided to use a New Beetle pre-immo harness and ECU, here is my diagram with which i have conjured up with voodoo and other mysterious powers. The important parts are the green highlighted areas. These are the wires to be spliced into the CE2 fuse box. The red highlighted area is a confusing part where two wires seem to go into the same connector, methinks this is an error in the Bentley.

http://pics.tdiclub.com/data/500/alhtoce2beetle.pdf

Here is the link to the original wiring diagram compiled by MrDave who has been an extraordinary help. Also I think there is some confusion in the bentley with the T14 and T14b connectors so I just added in the T14b connector and I think its just the T14 connector but oh well.

http://www.mrdavesworld.com/tdi/1998-ALH-NB-engine-diagram.pdf

Enjoy, Hope this helps.

Justin
 

dubCanuck1

Veteran Member
Joined
Oct 1, 2004
Location
Calgary, Alberta
TDI
2001 Jetta TDI, MKII/2002 ALH TDI (In progress)
Hi Justin,

Dave put me onto your thread for the harness. I just finally (after 6 years) tore into the wiring on my own project, so thank you for the link on the spliced harness. I'm running a 2002 ALH with 98 NB ECU/cluster in my 92 CE2 car. This is very helpful. I'll check to see what my interior harness looks like in terms of the "red, confusing" bits. It might just be that there are 2 wires pigtailed in a single connector...something I've seen a bit of, particularly last night.....

What did you use to build your schematic? I'll have to do something similar for mine
 
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