Replacement Engine

[rrgrassi]

Ok, I have a 2003 replacement ALH engine for my 2003 Golf. It is from an automatic, with 80,000 miles on it. Comes complete, minus the turbo.

My car is a manual, so I was advised by folks on this awesome forum, to get the engine from an auto, and swap over the manual's injectors. I will also be replacing the clutch as well, as my car died with 400K miles on it.

Engine will arrive next week.

 

[Rob Mayercik]

Correct - the auto had the larger (11mm) fuel pump, the manual got the larger injector nozzles. Definitely use the replacement engine's pump, when combined with your manual injectors you'll see a bit of a power increase over stock manual configuration.

But, here's another thought - since you'll have two sets of injectors, if the ones from your manual are in need of a refresh you could send them out for that and use the auto ones temporarily, then swap in the refreshed ones once you get them back.

With only 80K on them, the auto injectors should be in great shape, and with the auto engine's pump should feel pretty much the same power as your old engine did new.

 

[Sauaciden]

As far as I understood 90hp automatics had smaller injectors but bigger plunger in the injection pump (11mm vs 10 mm in manual) If you have plans on increase power, keep injection pump from auto as it will allow you to reach higher HP

 

[oilhammer]

You will also need to change the coolant flange on the head and the coolant crossover pipe, as those are also different.

 

[OkiHero]

I'm just gonna ride this wave since it's here. What's is a suitable and direct swap for a BEW with 09A?

 

[Nero Morg]

I'm just gonna ride this wave since it's here. What's is a suitable and direct swap for a BEW with 09A?

Another BEW.... With another 09A, or manual swap it.

 

[JDSwan87]

Another BEW.... With another 09A, or manual swap it.

Nailed it!

 

[OkiHero]

Another BEW.... With another 09A, or manual swap it.

Fair enough. I don't remember where someone said something about a BRM will go in but I probably will just stick with the BEW.

 

[rrgrassi]

You will also need to change the coolant flange on the head and the coolant crossover pipe, as those are also different.

I can get those from the old engine, right?

 

[rrgrassi]

I do plan on keeping the lower mileage IP. Getting the manual injectors rebuilt is a good idea. I wonder who in the DFW area does that. Any ideas?

 

[Nero Morg]

I can get those from the old engine, right?

Yes you can, just clean the bore the pipe goes into and replace the o ring for it.

 

[ghohouston]

I do plan on keeping the lower mileage IP. Getting the manual injectors rebuilt is a good idea. I wonder who in the DFW area does that. Any ideas?

M&D in Dallas probably will. There is also Abel injection in Lewisville. Im sure there are others, but those are the ones I know of.