Have a new car, missing my diesel...

[dodger21]

So I bought a $750 1998 Golf 4dr with a 2.slow. I love the car but miss my diesel. I am tired of dealing with IDI issues (glow plugs in top shape, lack of power, lack of aftermarket support) but I don't want an electric TDI. So I am planning on building a M-TDI. I have a Cummins 6bt pump core that I am selling some parts off of and getting a 12mm 4BT H&R. May build my own camplate. But anyways...

Which TDI long block should I look for? Now, all out power is not what I want BUT I want the capability to expand on my future "needs".   Also, for now, I am keeping the 2.0 trans but putting in a .75 5th until I can afford a newer TDI trans.

I have a source to get new injectors built to what ever specs I want. Also I will tune the pump to whatever the mood desires.

Readers Digest version: Which TDI long block minus pump should I get for longevity and power to replace the MK3 2.0?

[rallydiesel]

The ALH is best for a durable m-tdi. Aftermarket parts are easily found. The block is much more robust than the AHU/1Z, as can be seen from the extensive reinforcement in the casting.

However, the passenger side mount is completely different on the mk4 engines vs. the mk3 engines. So you would need to fabricate that mount.

[dodger21]

No problem with fabricating. I just got 600lbs of steel an old timer gave to me for free. He used to rebuild classics and created hot rods. He got out of the business and for a payment for helping him clean, I got what ever I wanted from a warehouse. 

We're talking 5" high 3/8" thick C channel, 1/8"-1/2" plates...

[BigVWman]

The ALH is best for a durable m-tdi. Aftermarket parts are easily found. The block is much more robust than the AHU/1Z, as can be seen from the extensive reinforcement in the casting.

However, the passenger side mount is completely different on the mk4 engines vs. the mk3 engines. So you would need to fabricate that mount.

man i gotta disagree on that one! the alh depends on being bolted to a 02a/j/m style trans with the oil pan to help support the block structure! it may look beefier but i doubt it is if not mounted to a newer style trans! i would go ahu, they are scarcer but the internals can be swapped in from an alh if need be.

[rallydiesel]

Well I would never bolt a alh to an 020 trans. That's like buying a Ferrari and putting Canadian Tire brand tires on it.  Ok, maybe not that bad. I'd definitely recommend a better than 020 trans with a performance build ALH. Although I do think someone on the vortex did an ALH swap into a Rabbit and used the 020 trans without issue.

[BigVWman]

You can put an alh to an 020 and it will work but it's block design looks for extra support from the trans bellhousing. May be a problem later on maybe not, just not how it was designed. Mrdave put an alh to an 020 in his legendary truck. however the engineers in designing the block included the trans/bellhousing support for some reason. There has been some discussion on it at tdi club in regards to its needing additional rigidity support.
The OP said right off the bat he was looking to go 020 until he can afford a tdi trans, now from personal experience i know often times temporary becomes permanent by procrastination, hence i would recommend the ahu/1z style block design! You can get similar performance numbers from an ahu as you can from alh anyway without some of the hassle.
 

[8v-of-fury]

Well I would never bolt a alh to an 020 trans. That's like buying a Ferrari and putting Canadian Tire brand tires on it.   Ok, maybe not that bad. I'd definitely recommend a better than 020 trans with a performance build ALH. Although I do think someone on the vortex did an ALH swap into a Rabbit and used the 020 trans without issue.

Yes, as said Mr.Dave did, and has been running it for years. Obviously everyone is aware of the 020's short comings. How often does a component fail under normal use? I have a trans in my car right now with over 525k miles on it.. Synchro's are a little worn, I feel it could be put behind a TDI and do just fine. Sure the engine makes double the torque of the 1.6d its been behind its whole life.. but its all how you drive.  Every piece of EVERYTHING ever designed or manufactured has a downfall.. Choose yours. The 020 will work just fine behind a stock 1Z/AHU engine, performance build? not too long Its all how you drive

You gonna drop the clutch a lot at 2000+? beat on it? track it? 020 is probably not for you.. HOWEVER! Many have their 020's behind built up 16v, 2.0L... turbo applications, some matching the TDI for torque output..

I have read stories of a fortified 02J being destroyed behind a mildly tuned ALH..

AHU and early 020 being the best combo to my knowledge. All three Gen's of 020's have downfalls (mk1, 2 and 3) the worst being in the 86.5+ transmissions like that found behind the 2.0L.. cant remember what is worse off hand though

[dodger21]

What's wrong with the 2.0 020? That is what I have... but I also have a AOP trans from a 87 or 88 jetta diesel too.

Right now, very little beatings. When I get a proper trans, some track use. I know what kills the trans is the torque at low rpm before everything is meshed together.

[R.O.R-2.0]

What's wrong with the 2.0 020? That is what I have... but I also have a AOP trans from a 87 or 88 jetta diesel too.

Right now, very little beatings. When I get a proper trans, some track use. I know what kills the trans is the torque at low rpm before everything is meshed together.

they crap the ring gear rivet heads.. make holes in the case. and the bearings dont last that well either..

i just replaced one, had holes all over it. and it was NOT ran dry of oil..