shortysclimbin
Veteran Member
Well I have finally held off to the point where I have most of the parts and info I need to get this build completed. The more I wait the more cool stuff I have found or been able to discover. I would like to first put out there that I have many hours and questioned a lot of people here and on other sites before I started this build thread. Many thanks to all of you for the help and guidance in the past and in the future I might receive on the thread here. Many of you have backgrounds and info that have allowed these ideas and changes to happen.
Background:
Project weight loss is my mk2 swap project that is replacing the performance side of my daily driver car. During my last build I found having one car (mk4 tdi jetta) as a jack of all traits car hindered what I could do with it in the long haul, and after having a few weekends of working in snowy really cold weather trying to do performance tweaks to get it just right I decided to split my ride into two cars. A mk2 performance oriented rig and a mk3 "winter beater."
The mk2 golf is mainly going to be used for track events and shows, but will still need to be street legal to get me to and from those events. This car is drastically lighter than the stock or modded tdi I was driving weighing in at only 2420lbs in its relatively stock shape. I am planning on removing the non daily needed items hence the name project weight loss.
For more info on the conversion and changes to the car besides engine related changes please visit my swap thread located here:
http://forums.tdiclub.com/showthread.php?t=199315
Now onto the engine:
Intro:
What we are starting with is a 1999.5 ALH tdi engine from a Jetta tdi that got crashed at 185k miles. I bought the whole car to get all of the swap parts in one swoop.
Electrical related:
The wire harness is being lightened and reduced on both the stock golf side and the engine management size. Basically the only wires we are concerned with in this thread run the engine only. So far what I have found this is only a total of around 6 fuses and three relays total!
Lower end:
The lower ends of the ALH block are much stiffer than an AHU block but not quite as sturdy as the pd130 and pd150 sister blocks and internals. Because of sourcing issues and the fact that I already had an ALH block it was a reasonable compromise to use this as a starting point of my buildup. The goal with the whole short block is to build something that will withstand any bolt on combination of parts that could be thrown at the engine itself. This will allow me to build the major portions of the bock and change out bolt on parts at will later. The parts I have chosen for the bottom end so far are as follows:
Forged lightened stock stroke crankshaft
Forged H rods designed for stock piston pins
81mm Oversized pistons
ARP rod bolts
ARP Main stud bolts
Girdle plate/ crank scraper
Total seal gapless piston rings
Modified OEM oil pan with baffles
These parts alone have lightened up the engine assembly a total of 10.5lbs and will drastically increase the strength over the stock assembly. And if you just did the math that opens up the system to become a 2.0L TDI engine. And on that note I basically just got everything in and will fill you guys in on more details of the machining work, coatings and other nitty gritty when they are done. I have a pile of parts sitting on my table right now and I am a kid in a candy store so I do need to go back to drooling over them with the calipers for a bit….
Upper end head assembly:
The head will have major port work done to it to increase airflow at higher rpms. I have also decided to go with a dual valve spring setup with titanium retainers to reduce any valve float we may be getting due to excessively high pressures. Overall the head is being built to handle higher RPMs and pressures. Head parts at this point are going to be the following:
a) PP performance camshaft (this may get changed out to any one of the other three cams on the market if I can get my hands on one with .5mm more lift throughout.)
b) Lightened Hydraulic lifters
c) Dual HD valve springs and light weight valve spring retainers
d) Stock intake valves will be used
e) Oversized swirl polished exhaust valves are in attempts to be made
f) The head will have drastic bits of porting done to it. (I do not think I will be doing this work myself).
So far here is a pretty parts picture for you to enjoy J
Ok so that’s it thus far. I will update you guys with more info here in a bit I have a lot of things that are being built and done at the same time. The build will also most likely go on for a while due to this being a part time project. So does anyone have any questions, comments or suggestions?
(Edited to have links)
Background:
Project weight loss is my mk2 swap project that is replacing the performance side of my daily driver car. During my last build I found having one car (mk4 tdi jetta) as a jack of all traits car hindered what I could do with it in the long haul, and after having a few weekends of working in snowy really cold weather trying to do performance tweaks to get it just right I decided to split my ride into two cars. A mk2 performance oriented rig and a mk3 "winter beater."
The mk2 golf is mainly going to be used for track events and shows, but will still need to be street legal to get me to and from those events. This car is drastically lighter than the stock or modded tdi I was driving weighing in at only 2420lbs in its relatively stock shape. I am planning on removing the non daily needed items hence the name project weight loss.
For more info on the conversion and changes to the car besides engine related changes please visit my swap thread located here:
http://forums.tdiclub.com/showthread.php?t=199315
Now onto the engine:
Intro:
What we are starting with is a 1999.5 ALH tdi engine from a Jetta tdi that got crashed at 185k miles. I bought the whole car to get all of the swap parts in one swoop.
Electrical related:
The wire harness is being lightened and reduced on both the stock golf side and the engine management size. Basically the only wires we are concerned with in this thread run the engine only. So far what I have found this is only a total of around 6 fuses and three relays total!
Lower end:
The lower ends of the ALH block are much stiffer than an AHU block but not quite as sturdy as the pd130 and pd150 sister blocks and internals. Because of sourcing issues and the fact that I already had an ALH block it was a reasonable compromise to use this as a starting point of my buildup. The goal with the whole short block is to build something that will withstand any bolt on combination of parts that could be thrown at the engine itself. This will allow me to build the major portions of the bock and change out bolt on parts at will later. The parts I have chosen for the bottom end so far are as follows:
Forged lightened stock stroke crankshaft
Forged H rods designed for stock piston pins
81mm Oversized pistons
ARP rod bolts
ARP Main stud bolts
Girdle plate/ crank scraper
Total seal gapless piston rings
Modified OEM oil pan with baffles
These parts alone have lightened up the engine assembly a total of 10.5lbs and will drastically increase the strength over the stock assembly. And if you just did the math that opens up the system to become a 2.0L TDI engine. And on that note I basically just got everything in and will fill you guys in on more details of the machining work, coatings and other nitty gritty when they are done. I have a pile of parts sitting on my table right now and I am a kid in a candy store so I do need to go back to drooling over them with the calipers for a bit….
Upper end head assembly:
The head will have major port work done to it to increase airflow at higher rpms. I have also decided to go with a dual valve spring setup with titanium retainers to reduce any valve float we may be getting due to excessively high pressures. Overall the head is being built to handle higher RPMs and pressures. Head parts at this point are going to be the following:
a) PP performance camshaft (this may get changed out to any one of the other three cams on the market if I can get my hands on one with .5mm more lift throughout.)
b) Lightened Hydraulic lifters
c) Dual HD valve springs and light weight valve spring retainers
d) Stock intake valves will be used
e) Oversized swirl polished exhaust valves are in attempts to be made
f) The head will have drastic bits of porting done to it. (I do not think I will be doing this work myself).
So far here is a pretty parts picture for you to enjoy J
Ok so that’s it thus far. I will update you guys with more info here in a bit I have a lot of things that are being built and done at the same time. The build will also most likely go on for a while due to this being a part time project. So does anyone have any questions, comments or suggestions?
(Edited to have links)
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