jhax's Built ALH into a MK2 Golf thread

jmodge

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2001 alh Jetta, RC2 w/.205's 5speed daily summer commuter and 2000 alh Jetta 5spd swap, 2" lift, hitch, stage 3 TDtuning w/.216's winter cruiser, 1996 Tacoma ALh
well, I see you have a pvc valve on the cover. Maybe pull that off and run a hose off the cover to see what is going on. Get the oil level correct and the fuel turned down to start. Looks like lots of juice that isn't being burnt making it to the turbo, unless it is the turbo. That could be a runaway in the making
 

jhax

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96 Passat B4V, ALH engine out of a 2002 Jetta, some IE Rods and ASV Pistons. Nothing drivable yet though
Well my dumb ass just remembered that without an intercooler and IC hoses plumbed, of course it's just going to dump fuel into the motor. I got so excited the other night that I got it to start that I completely forgot about that aspect.
 

jmodge

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2001 alh Jetta, RC2 w/.205's 5speed daily summer commuter and 2000 alh Jetta 5spd swap, 2" lift, hitch, stage 3 TDtuning w/.216's winter cruiser, 1996 Tacoma ALh

jhax

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96 Passat B4V, ALH engine out of a 2002 Jetta, some IE Rods and ASV Pistons. Nothing drivable yet though
That is correct I have not done the initial break in procedure. Which one would you recommend?
 
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jhax

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96 Passat B4V, ALH engine out of a 2002 Jetta, some IE Rods and ASV Pistons. Nothing drivable yet though
 

jhax

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96 Passat B4V, ALH engine out of a 2002 Jetta, some IE Rods and ASV Pistons. Nothing drivable yet though
Got the exhaust back today.

 

jhax

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96 Passat B4V, ALH engine out of a 2002 Jetta, some IE Rods and ASV Pistons. Nothing drivable yet though
Got intercooler all hooked up and I'm thinking over post due to too much fueling? I am wondering if it would be a start to advance my timing by rotating the pump to the rear of the car prior to starting it up again. When I first start the car it seems like it bogs for a few seconds, then the turbo kicks in which causes the engine to rev up to 3500-4k, it sounds like an boost pipe boot disconnects and the car shuts off. White smoke so thick you can cut it with a knife spews everywhere, smells of diesel.

 
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jmodge

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Greenville, MI
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2001 alh Jetta, RC2 w/.205's 5speed daily summer commuter and 2000 alh Jetta 5spd swap, 2" lift, hitch, stage 3 TDtuning w/.216's winter cruiser, 1996 Tacoma ALh
did you clean that turbo out?
 

jhax

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96 Passat B4V, ALH engine out of a 2002 Jetta, some IE Rods and ASV Pistons. Nothing drivable yet though
I did, I also advanced timing, it started better but still copious amounts of smoke and engine died. I pulled my plugs and they are sooty and damp. I wonder if my nozzles are sticking open. They are brand new dlc1019s from dbw is there a way to check them while they are in the car? Can I pull the plugs, crank and check for excess fuel out the glow plug holes? Or would that potentially cause uneven detonation and really destroy some stuff?
 
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jhax

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96 Passat B4V, ALH engine out of a 2002 Jetta, some IE Rods and ASV Pistons. Nothing drivable yet though
After doing more reading I suspect it may also be that my IQ level is too high. I dont suspect I could get the car running long enough (even to allow it to warm up) to mess around with the IQ. Is there a way to be able to adjust via the hammer mod (less fuel) with the car off and cold? Just so I can get to a stable idle?
 

aNUT

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'01 TT (ALH-ish), B7 Audi gasser, '05 Golf
You can just loosen the bolts that secure the QA to the pump case a quarter turn and give it a couple whacks towards the belt end of the engine. That direction is less fuel (higher reported IQ). Once you get the idle to stabilize you can interrogate with VCDS & dial it to your liking.
 

jhax

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96 Passat B4V, ALH engine out of a 2002 Jetta, some IE Rods and ASV Pistons. Nothing drivable yet though
Thank you for the reassurance sir.
 

jhax

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96 Passat B4V, ALH engine out of a 2002 Jetta, some IE Rods and ASV Pistons. Nothing drivable yet though
Alright! Got it to idle, still isn't happy about it and starts to run away after key out. Looks like ill need to hammer mod a bit more. I suspect the 11mm pump and 1019s, fueling is through the roof.
 

ToddA1

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'96 B4V, '97 B4 (sold), '97 Jetta (scrapped)
I stopped getting notifications and don’t think I saw anything since October... glad to see it’s running! You’ll get it figured out.

-Todd
 

jhax

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96 Passat B4V, ALH engine out of a 2002 Jetta, some IE Rods and ASV Pistons. Nothing drivable yet though
Thanks Todd, I was wondering when you would chime in. After shutting it off yesterday (by shoving my hand over the intake pipe to restrict air) I noticed what looks like oil spraying from out of either the injector or the glow plug hole in an upward direction onto the head behind the injector. I didnt get a chance to smell if it was fuel or oil. Looks like something may need to be tightened down. I hope it isnt oil bypassing the rings, although the rings are brand new and I definitely installed them correctly. Perhaps they havent sealed properly yet, which would make sense since the care has only been started a couple times.
 

jhax

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96 Passat B4V, ALH engine out of a 2002 Jetta, some IE Rods and ASV Pistons. Nothing drivable yet though
Well im ditching the two plugs going from the fuse/sci to engine and crimping all the wires. I noticed my n75 was vacuumed wrong and broke one of the nipples removing the hoses. Bought a new n75, might as well have.

Its unclear what my voltages should be at pin 2 on the n75. It's a pwg signal from the ecu so if you put + at pin2 and - to ground with key in on position you should see ?v varying between two numbers?
 

jhax

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96 Passat B4V, ALH engine out of a 2002 Jetta, some IE Rods and ASV Pistons. Nothing drivable yet though

jhax

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96 Passat B4V, ALH engine out of a 2002 Jetta, some IE Rods and ASV Pistons. Nothing drivable yet though
So I got the basic 3 bar tune from kerma and it is running much better, much less Smokey. I get the following codes though, and it does not shut off when I switch off the key. I checked voltage at the injection pump, pin 5 for n146 power and I am getting battery voltage.

When I hammer towards belt iq reads 0, even with significantly harder taps. If I tap towards trans a couple times, iq creeps upward through teens and up to 20s by its self. I managed to get iq at between 4.2 and 5.2 (would jump around on its own) before shutting it off because I was starting to take a really hot shower.

Tuesday,22,December,2020,13:46:12:42667
VCDS -- Windows Based VAG/VAS Emulator Running on Windows 7 x86
VCDS Version: 20.12.0.1
Data version: 20201125 DS322.1
www.Ross-Tech.com




Address 01: Engine Labels: 038-906-012-AGR.clb
Control Module Part Number: 038 906 012 GN
Component and/or Version: 1,9l R4 EDC G200SG 4308
Software Coding: 00002
Work Shop Code: WSC 00066

VCID: 62C55DDBEEE91A9474-4ACE
5 Faults Found:

17849 - EGR Valve (N18)
P1441 - 35-10 - Open Circuit or Short to Ground - Intermittent
17969 - Quantity Adjuster (N146)
P1561 - 35-00 - Control Deviation
18058 - Powertrain Data Bus
P1650 - 35-10 - Missing Message from Instrument Cluster - Intermittent
17068 - Glow Plug Control Module (J179)
P0684 - 35-10 - Implausible Signal - Intermittent
17971 - Quantity Adjuster (N146)
P1563 - 35-00 - Lower Limit Reached

Readiness: 1 5 0 0 0

--------------------------------------------------------------------------------
--------------------------------------------------------------------------------


Address 01: Engine (038 906 012 GN)

14:00:10 Group 025





14:00:10 Group 001: Injection Quantity
882 /min Engine Speed (G28)
4.4 mg/str Injection Quantity
4.520 V Mod. Piston Disp. (G149)
96.3蚓 Coolant Temperature (G62)

14:00:10 Group 004: Start of injection
903 /min Engine Speed (G28)
0.4 蚪TDC Start of injection Specified
22.9 蚪TDC Start of injection Actual
94.4 % Cold Start Injector Duty cycle
 

jhax

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Location
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96 Passat B4V, ALH engine out of a 2002 Jetta, some IE Rods and ASV Pistons. Nothing drivable yet though
Another thing of note, the glow plug fault. These are new plugs with a new harness and new relay. All wires with the exception of the plug wires are in the cabin. This is a recent development. The light comes on and shuts off after a second. I am getting power to the relay through the single 50a fuse I have in there. The plugs are wet with fuel. I changed the relay with another new one and the fault goes away but the light only cycles for a second. I only get an error when I turn key on and go to the glow plug controller in vcds. It is below 40° here today. Any help would be appreciated. I feel like I've been talking to myself lately.
 

jmodge

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Location
Greenville, MI
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2001 alh Jetta, RC2 w/.205's 5speed daily summer commuter and 2000 alh Jetta 5spd swap, 2" lift, hitch, stage 3 TDtuning w/.216's winter cruiser, 1996 Tacoma ALh
How long have your injectors been sitting unused?
 

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
They sat in the motor for up to 2 years, dry, with the dry fuel lines screwed into them, no dust or grime could have gotten into them. The car starts and runs.
 
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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
A small update. I went back and re-connected all of my wires going to the engine bay. I previously had all wires going to two separate T14a plugs from the inside of the fender and then to the motor via the other side of the plugs. I removed the plugs and crimped all of the wires with the waterproof crimps, replaced my N75, and added solder sleeves to my Crank and Needle lift cables on the motor side in order to maintain shielded ground through the length of wire. The car started but only when I jump start it. I let it warm up and adjusted IQ and static timing. My computer died while I was doing the static timing test so I have to revisit that, hopefully today. My lack of glow plugs I found out are caused by my removal of pin 88 in the ecu thinking it was not necessary (based on the ALH pin out on this forum), turns out since the ECU I am using is from 2003, it is necessary. I am also seeing my tachometer reading 3000 RPM while the car is idling. I know it is a direct reading from the ALH ECU to the MK3 instrument cluster and nothing is required to alter the signal, so I need to figure out what is going on there as well. But the good news is, now the car shuts off with key off so that means my IQ is in better shape than it was.
 
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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
Seems like I've got glow plugs back. With coolant plug unplugged the light stays on for about 15 seconds. Moving on!
 

jhax

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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
The car now idles and all engine related fault codes are gone. Unfortunately it only starts when IQ is set very high in my opinion. I let it idle until it was warm and got IQ to abut 4.6 and static timing is as ~8*BTDC. I just attempted to start while logging 000, 001, 004 and 005, can someone please take a look?

Code:
Address 01: DTCs clearedFriday,08,January,2021,16:57:20:42667
VCDS -- Windows Based VAG/VAS Emulator Running on Windows 7 x86
VCDS Version: 20.12.0.1
Data version: 20201125 DS322.1
www.Ross-Tech.com
--------------------------------------------------------------------------------
--------------------------------------------------------------------------------


                Address 01: Engine  (038 906 012 GN)

16:57:11 Group 000: Basic Functions - Switch to Basic Settings for Start of Injection
  000  Engine speed (G28)  - Specification (Idle): 41...46 (861...950 RPM) | (Full Load): 138...148 (2900...3100 RPM)
  038  Start of Injection - Specification (Idle): 12...75 (2 °ATDC ... 4 °BTDC) | (Full Load): 137...215 (8...14 °BTDC)
  000  Throttle Position - Specification (Idle): 0 (0 %) | (Full Load): 255 (100 %)
  000  Injected Quantity - Specification (Idle): 11...45 (2.2...9 mg/stroke) | (Full Load): 199...214 (39.8...42.8 mg/stroke)
  095  Manifold pressure - Specification (Idle): 83...106 (920...1140 mbar) | (Full Load): 179...215 (1850...2250 mbar)
  167  Atmospheric Pressure  (BARO metric) - Specification (Full Load) 183...224 (910...1110 mbar)
  188  Coolant Temp. (G62) - Specification: 80...35 (80...110 °C)
  190  Intake Manifold Temp. (G42). - Specification: 182...50 (10...100 °C)
  064  Fuel Temp. (G81) - Specification: 91...201 (20...80°C)
  255  Air Mass (EGR On - 2 Min. after start-up) - Specification (Idle): 69...111 (230...370 mg/H)

16:57:11 Group 001: Injection Quantity
  0 /min  Engine Speed (G28)
  0.0 mg/str  Injection Quantity
  0.740 V  Mod. Piston Disp. (G149)
  6.3°C  Coolant Temperature (G62)

16:57:11 Group 005: Starting Conditions
  0 /min  Engine Speed (G28)
  0.0 mg/str  Start Injection Quantity
  0.0 °BTDC  Start Injection  Actual
  6.3°C  Coolant Temperature (G62)
Group A:'000'001'004'005
Engine SpeedInjection QuantityMod. PistonCoolantEngine SpeedStart of injectionStart of injectionCold Start InjectorEngine SpeedStart InjectionStart InjectionCoolant
TIME(G28)Disp. (G149)Temperature (G62)(G28)SpecifiedActualDuty cycle(G28)QuantityActualTemperature (G62)
MarkerSTAMP/minmg/strV°C/min°BTDC°BTDC%/minmg/str°BTDC°C
0.28​
0​
38​
0​
0​
94​
167​
189​
190​
64​
255​
0​
0​
0.74​
6.3​
0​
11​
0​
94.4​
0​
17.6​
0​
6.3​
1.32​
0​
38​
0​
0​
94​
167​
189​
190​
64​
255​
0​
0​
0.72​
6.3​
0​
11​
0​
94.4​
0​
29.2​
0​
6.3​
2.36​
0​
38​
0​
0​
94​
167​
189​
190​
64​
255​
126​
29.4​
0.74​
6.3​
231​
11​
0​
21.5​
252​
29.2​
0​
6.3​
3.4​
11​
38​
0​
147​
94​
167​
188​
190​
64​
78​
189​
30.6​
2.24​
6.3​
252​
11​
0​
20.7​
189​
32.8​
0​
6.3​
4.43​
11​
38​
0​
166​
94​
167​
188​
190​
64​
79​
231​
34.6​
2.34​
6.3​
252​
11​
0​
23.1​
231​
36.8​
0​
6.3​
5.47​
9​
38​
0​
186​
94​
167​
188​
190​
64​
90​
189​
38.8​
2.4​
6.3​
252​
11​
0​
20.3​
210​
40.8​
0​
6.3​
6.49​
9​
38​
0​
207​
94​
167​
188​
190​
64​
84​
252​
42.8​
2.52​
6.3​
231​
11​
0​
23.1​
210​
44.8​
0​
6.3​
7.48​
11​
38​
0​
227​
94​
167​
188​
190​
64​
80​
231​
46.8​
2.56​
6.3​
231​
11​
0​
22.7​
189​
48.8​
0​
6.3​
8.44​
9​
38​
0​
247​
94​
167​
188​
190​
64​
85​
252​
50​
2.62​
6.3​
189​
11​
0​
22.7​
210​
50​
0​
6.3​
9.39​
11​
38​
0​
250​
94​
167​
188​
190​
64​
79​
231​
50​
2.62​
6.3​
231​
11​
0​
23.1​
252​
50​
0​
6.3​
10.33​
12​
38​
0​
250​
94​
167​
189​
190​
64​
71​
231​
50​
2.6​
6.3​
231​
11​
0​
25.5​
210​
50​
0​
6.3​
11.25​
12​
38​
0​
250​
94​
167​
188​
190​
64​
71​
231​
50​
2.6​
6.3​
231​
11​
0​
23.1​
210​
50​
0​
6.3​
12.2​
11​
38​
0​
250​
94​
167​
188​
191​
64​
89​
231​
50​
2.58​
6.3​
252​
11​
0​
22.7​
252​
50​
0​
6.3​
13.14​
11​
38​
0​
250​
94​
167​
188​
190​
64​
83​
189​
50​
2.58​
6.3​
231​
11​
0​
20.7​
252​
50​
0​
6.3​
14.07​
9​
38​
0​
250​
94​
167​
188​
190​
64​
91​
252​
50​
2.62​
6.3​
231​
11​
0​
25.5​
252​
50​
0​
6.3​
15.01​
9​
38​
0​
250​
94​
167​
188​
190​
64​
88​
252​
50​
2.62​
6.3​
189​
11​
0​
25.5​
126​
0​
0​
6.3​
15.93​
12​
38​
0​
250​
94​
167​
188​
191​
64​
74​
252​
50​
2.62​
6.3​
252​
11​
0​
25.9​
16.88​
12​
38​
0​
250​
94​
167​
188​
190​
64​
63​
231​
50​
2.6​
6.3​
231​
11​
0​
23.1​
17.8​
11​
38​
0​
250​
94​
167​
188​
190​
64​
126​
231​
50​
2.6​
6.3​
252​
11​
0​
23.1​
18.73​
11​
38​
0​
250​
94​
167​
188​
190​
64​
83​
189​
50​
2.58​
6.3​
252​
11​
0​
20.3​
19.66​
9​
38​
0​
250​
94​
167​
188​
190​
64​
93​
231​
50​
2.6​
6.3​
252​
11​
0​
23.1​
20.58​
11​
38​
0​
250​
94​
167​
188​
190​
64​
83​
231​
50​
2.6​
6.3​
231​
11​
0​
25.5​
21.49​
9​
38​
0​
250​
94​
167​
188​
190​
64​
84​
252​
50​
2.62​
6.3​
189​
11​
0​
25.9​
 

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
After a functioning N108 replacement, thank you @aNUT and the much delayed purchase of a crank lock tool, thank you @Metalnerd Gramps fired right up! No critical engine codes thrown and now I am ready to put a brick on the throttle and let it idle at 2000-2500 rpm for 20 minutes in order to get this camshaft broken in. Maybe I am being too over analytical, but when you are breaking in a cam, you are supposed to immediately bring it up to the RPM. But if you are doing a brand new engine build you need to fiddle with IQ and timing, both require the motor to be warm and idling. If that is the case, should the act of letting it idle until warm mess with the cam break-in?
 

CasaEd

Veteran Member
Joined
Mar 18, 2017
Location
Portugal
TDI
VW Passat TDi B4, VW Passat TDi B4 GL, VW Passat B3 PD AWX Conversion
In Europe there are two different instrument clusters, one has an analog tacho, the other digital. do you know which one you have in your car ?
 

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
Mine is a digital cluster from a MK3 Jetta TDI. I grounded the fuse box (G1/5) to the head but that hasn't resolved the problem. I wonder if the wire going to the rev counter (from pin 27 on the ecu) is picking up noise from somewhere. I have the wire going to one of the mk4 rectangular T10 plugs behind the heater core next to the firewall. I am almost thinking if I took that one wire out of the plug and spliced it together if it would solve the problem.
 
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