THIS is the MOST Important Part Of Any Engine Rebuild/ ALH TDI Overhaul

The most important part of any rebuild is measuring all the clearances and double checking the machine shops work. As seen in the video, many mistakes can be found!!
Follow me on instagram! / austinniemela
Some tools used here:
Bore Gauge: amzn.to/2YmqvoF
Mag Base Dial Indicator: amzn.to/2AUQHOg
T Handle Bore Gauge Set: amzn.to/37POFLF
Micrometer Set: amzn.to/3hRVeSf
Depth Gauge: amzn.to/3etmMLW
Sony A7II Camera: amzn.to/2yprn1p
GoPro Hero 8 Black: amzn.to/31avsTg
Toyota Build List:
docs.google.com/document/d/1r...

[@kevinbrewer1685]

I've done this all my life and I'm almost 50 . Everything you done looked very professional. But don't look at plasta-gauge as a cheep alternative!! It is not. It is a verification of all your work!! Do not forget that. I like the tdi's and I like your vid's thank you for the time you put into then!

[@UlisesGlez26]

Damn man, you would think everything is supposed to be perfect when you go to a "professional" shop, glad you guys are smart and double check everything.

[@thefun-v2466]

I enjoy that you share your process with us and we get to see how you learn and you're humble enough to admit mistakes and are able to take action to correct them Sometimes things are outside of our control and it's cool to see how you roll with it. Thank you for making and sharing these videos and I look forward to seeing how your projects progress.

[@austinniemela]

Thanks!! I hope you are enjoying the video!! 👍

[@OffGridOverLander]

One nice thing about the medium and heavy truck engines like I have is that they are wet sleeves, meaning the rebuild kit comes with everything already spec’d out by Cummins and comes with the new liner. Makes an in-frame rebuild so much easier than what I’ve had to deal with on gassers or light duty truck engines, like the powerstroke and the 5.9

[@daniel22mckee]

Thank you for finally posting a ALH engine build I’m going to be doing one for my car in the future so it’s nice to see what I need to look for when I go to do it

[@Dalan612]

Man, I just wanted to say that I really appreciate your videos. Been watching for some weeks now and I'm super thankful for this type of information, super legit of you for sharing and tremendously helpful. Please keep it up! I'm subscribing.

[@austinniemela]

I appreciate that! Glad i can help!!

[@whrswaldo1]

Just wanted to do a shout out and say thank you. My 03 alh had some piston rings go bad when the #3 injector failed and washed out the motor. Having never done more than a head gasket before this, your videos helped me rebuild the entire motor, check the specs and tolerances and I love the channel and all the things you're doing. Honestly don't think I would have tackled this project had I not found this build. Thank you

[@austinniemela]

Awesome!! Il glad I could help out!

[@maxospreys2964]

You are on another level brother, that Go-Pro just made more clear and easy to follow. Awesome.

[@hussainzada79]

Bro everytime I'm watching your video I am learning new things keep going god bless you

[@Timr45_70]

You are incredible for detail! I'm just in awe.

[@alanboyce7109]

What a nice clean shop! BEAUTIFUL! with LOTS OF ROOM!

[@otylerhd4984]

great video im learning alot from your videos i have a alh aswell with ported head, colt cam, ported pd150 intake, 1752 turbo,11mm pump and race 520 it runs really well im looking to do the bottom end this winter so this is very helpful information for me thanks for the content keep up the great work man, truck looks sweet

[@ronthompson2366]

I am a machinist and mechanic and have been my entire life... many more decades than I care to admit. Just seeing you take the time to spec everything out is impressive. Never take the word of the shop, unless you have a close working relationship with them routinely for a long time. Shops make mistakes, things go wrong, what ever , but if you don't check it is then your word against thiers and or you end up with a failed even more costly rebuild. Plastic gauge is a good tool in addition. Make sure you verify ring gap as well. Your blue printing the build, continue to take the time to check the spec's. The little things now will save you in the long run and the overall finish is worth the time spent. Looking forward to seeing your next episode...

[@austinniemela]

Ron Thompson ring end gap will be checked once I have a bore I’m happy with!!

[@davepelfrey3958]

Really good and informative video. This was a really good catch. Can't wait to see what happens next. Stay safe.

[@citabria4804]

10:55 Your kid seems like they want to rebuild a TDI!

[@nickmarangos2475]

One of the top 4 VW diesel engines if not the best freaking bullet proof and can hold loads of power!!love your build!

[@jimmybates1972jcb]

Can't wait to see it finished. Don't know how you will to this awaiting patently. Keep up the good work

[@aygwm]

Really helpful and thorough video. About to rebuild an AHU TDI engine... first engine rebuild. wish me luck.

[@MussaKZN]

If this was a Toyota 1KZ-te rebuild, I REST MY CASE!! Nice work Bro!!!

[@denaiw6887]

yay the day we have!!! been waiting for...

[@veiri86]

Excellent skill. Subscribed. All the best from Dubai 😊

[@chriswise6374]

hey man, I am doing my first engine build currently and I wanna let you know how great this video is and how helpful it is. Thank you

[@austinniemela]

I’m glad I can help!!

[@kristofertrikones1339]

Like your content better than both of your brothers channels, can’t wait till you get more support for more builds. Underrated channel!

[@Onelonehonky]

So I got a little 1.3 samurai engine I need to send you to build for me. I need in the neighborhood of 120 hp. Stock is about 62 but I can bet you can double it. So what do you say? Super nice job on the engine build, it sucks that the bore and/or hone job didnt come out right. Hopefully it was machine error and not machinist error, and they make it right for you either way. Cant wait for the assembly video, make sure you dont leave us out on anything!! Thanks for all you do with this channel man cause you sure are teaching folks like me a lot.

[@jandkwhite6459]

Hell yea man been waitin!

[@yusufrimawi982]

Awesome video! Where did you get the repair manual? I've got a 1.9 BRM I need to rebuild.

[@spooks7630]

Hey Austin so what did you go with for Pistons and rods and what site did you use? Thank you. Sorry if I missed it if you mentioned it I've been watching this series as I'm slowly building mine now

[@poormofo1]

Damn bro. Impressed.

[@smplyizzy]

99% of people don’t have the ability to check their work like you did.

[@johnnyhernandez8530]

I'm in the 99% but I'm learning. Wish more kiddos would get off the games and learn some of this stuff

[@johncourtneyscott2757]

No wander why your so good at this!! It’s in your blood

[@ClumsyToast]

100th comment, booyah! Haha. Fun stuff. Love those ALH's. Why do companies stop making things that work wonderful?!?

[@user-oh3xj3jn3h]

Hey very nice video on the alh rebuild. Everything was explained very well. So I am looking at rebuilding one of my alh engines for some more hp. I wasn’t sure if the rods you had were for more hp or not. I saw the pistons were aftermarket due to the oil galley the stock one lack. I guess my question is where can I order rods, bearings and pistons from. Max hp would be 300 if that. Very nice build. Hope you are enjoying your new to you 3 years ago truck. Thanks any help is appreciated!

[@ivoivanov4467]

good video i am rebuilding my axr pd engine with a new block from asz to use the stronger cam and pistons

[@melvinsmutters7662]

Hey Austin can you make a short video about how to build one of these for the utmost reliability. I have in mind the life span of an industrial engine. Is a crank girdle helpful? Head studs? H beam rods?

[@urugly5917]

What pistons and rods did you use got links

[@krahnscheka6584]

hello, i wanted to ask if you have to install a thicker gasket after planning the cylinder head?

[@edgarramirezvazquez1622]

Que chingon karnal todo lo que le haces ala troka me dan ganas de aprender hacer todo eso de verdad que mucha admiracion por tu travajo ya que en la actulidad sufrimos para encontrar mecanicos buenos y sinseros en la acyulidad todo esta atrofiado saludos hermano ojala un dia hagas un video en español

[@gabrielthecolorblindsoul6994]

Are hypereutectic pistons good for a lot of miles and some extra hp? (compared to the stock, normal cast, pistons)

[@eddygoodwin7089]

At 23:20 your gauge is going to vary quite a bit if it gets tilted as you lower it down. Someone probably already mentioned this

[@ventura9513]

Gday mate,,,, just wondering are you a mechanic or diesel fitter by trade?? Can see you've done engines before in the way you measured clearences, not your average joe knows this stuff,, i'm a diesel fitter and noticed the way you were you were doing things is pretty spot on, cant fault your skills mate,, cheers from Australia

[@austinniemela]

nigel hill thanks!! No I am no diesel mechanic by trade, I have rebuilt motors in the past

[@kizomanizo]

@@austinniemela So this is all hobby? Wow!

[@TheAbrunqaj]

I just had my 03 ALH rebuilt by some guy that now doesn't want to work on it anymore. I'm not very knowledgeable about this engine. But now after the rebuilt, I'm getting low pressure light and beep. Also low oil level. I checked the level and it's good. I changed the sensor on the filter housing. The only thing that he didn't change was the oil pump. Should I go ahead and change that too ? I also just changed the bad turbo today and still same issue. I was also reading online that I can try to use a thicker oil .

[@markderksen7452]

Hey, Austin, where do I find engine spec's for the ALH?

[@gabedaxe477]

Amazing video

[@TheMot616]

Great content

[@jackcavo627]

Hey Austin, what rods did you use? And would you recommend them?

[@editz3234]

Austin, How did you measure wrist pin clearance when assembling the rods and pistons? If not how do you know that you don't have to check? Im about to do a rebuild but I'm curious as to how that part works. thanks

[@joshkelly3682]

Loves all your videos man, they are awesome!! I am doing an alh swap into a Suzuki sidekick right now. I'm sure this has been asked but what rods, pistons, rings, etc did you use? I are trying to find all the part numbers so I can get started on my motor. I am wanting to do your exact process and parts. Are those maspeeding connecting rods? I am wanting to do the asv pistons I think too. But is there an advantage to the lower compression of the arl's?

[@austinniemela]

Thanks man! Yes maxpeeding rods, asv pistons. I would honestly do arl or even better bore it to 2.0 and do bhw pistons, that’s the best piston out there!

[@shpplman6]

Did you have anything special done to the head? Just curious if it was a standard valve job or if you had it ported and polished, larger valves, or double springs or anything if that nature.

[@twelch3man]

Awesome video! I’m about to go through my BRM engine. What is the oil pump upgrade you referred to?

[@austinniemela]

Thanks! The BRM pump sprocket on the ALH pump spins the pump faster building more pressure!

[@alfajtd4301]

which connecting rod bearings did you use?

[@PintilieVasile]

Hello. Where did your dad got that 27 hole machinest block? All I can find is the smaller 23 hole block.

[@johncourtneyscott2757]

Good thing you checked

[@ugi5551]

Where did you get the new parts?

[@melekk0]

heyy , i have a question please , ive read on the bentley of a golf 2 that the diameter can go up to 0.08 from nominal dimension , and the piston to cylinder clearance should be 0.03 and 0.07 maximum allowable , 81.01mm cylinder bore standard , piston diameter 80.98mm , so if i have a value on my bore cylinder of 81.09 (81.01+0.08) im okey and still in the limit however its gonna be a clearance of 0.11mm ! which is over the max allowable piston to cylinder clearance 0.07 can u explain this to me please ?

[@matthewlee2686]

I miss all this TDI content

[@chriswise6374]

Hey man, where do you get all of these procedures' information, and all of the specs? Is there a book I can buy for this engine? Thank you :D

[@austinniemela]

Use the Bentley manual

[@formerfarmer1718]

No ring compressor? WTH! How is this done?

[@MJPilote]

Well no wonder you got different readings. You need to use a micrometer stand, not to heat it up in your hands. And to be more precise, measure at least 6 times to get an average. That reduces the measuring error margin. Other than that, nice work on the engine.

[@ALIREZAMOHAMMADSHAH]

does every motor that comes out of car companies have the same process as on these videos? it doesn't seem like a bulk process, i don't know much about car engines and i haven't seen these much work in shops either, they usually just change some parts and call it a day

[@d1bigshifter737]

Im throwing a p303 code . Injectors are fine timing belt is fine . Im going to do a pressure check , other than that what can i look for . 2002 1.9 diesel jetta auto trans

[@austinniemela]

What’s timing at? For sure do compression test

[@ZachdkingNH]

Awesome video, I'm building my first ALH right now and have referenced it a few times. Very helpful. But, how in the world are your pistons going in so easily?I'm using the same Nural oversized ones and there's no way I could get them in without a compressor. Obvi my block has been honed, but maybe my machinist got it wrong...

[@MagicMahn]

How's your build going?

[@matthewlee2686]

Yea no response.....

[@melvinsmutters7662]

Also whose your head guy! I gotta get my alh head done!

[@csabakamaras2820]

Thank you so much

[@austinniemela]

You're most welcome

[@1873Winchester]

You don't seem too upset about the shape and condition of the bores? Is the engine still usable with bores like that?

[@juderoy1473]

Can you add the torque and tolerance spec sheet in the description ???

[@austinniemela]

Jude Roy if you’re doing any engine work, a Bentley manual is worth its weight in gold!

[@mlowe30]

Really nice work! You need to get that little one a set of overalls and let her get dirty with you. 😊

[@dawidxcom6233]

300hp+ set?

[@VWPassat_3BG]

From where you got the factory rebuild specs please?

[@austinniemela]

Buy a Bentley manual!! They are amazing

[@kraabol.mp4]

Did you reuse the mains bolts after you torqued them to check clearance?

[@austinniemela]

They aren't torqued to the final spec during the measuring so no I do not replace them. DO use NEW bolts, as they are a TTY bolt

[@kraabol.mp4]

I'm seeing a lot of different opinions on torque spec like 22ft lbs or 22 ft lbs + 90°. Oil bolts or thread lock or non before install. Curious of your thoughts on this

[@justinrrizzo]

Can you explain the cutting procedure at 19:00 to me like I am a 3 year old?

[@vettepicking]

If your telescopic gages are a off-brand they will never measure to the half thou. To many poor finishes inside the tool compared to a starrett gage. Plus measuring soft babbit bearings the gage will dig in to the surface and measure larger because the way you tighten the telescoping gage.

[@spaight711]

A depth mic is much more accurate than a dial indicator and easier to use for that application.

[@OFFLlNER]

I will try repair my audi 1.9 tdi avx engine.

[@davea2407]

I can hear those bearings screaming now where is the ultra slick

[@vettepicking]

Most of my gas engine bore clearances are .001" per inch of the diameter of the piston. 3" bore = .003" clearance.

[@austinniemela]

vettepicking this is no gas and factory spec is .0016”

[@vettepicking]

@@austinniemela www.enginebuildermag.com/2014/08/demands-diesel-pistons-sleeves/ some go .003-.013" for high boost . Diesel motors make alot more heat which needs more clearance.

[@69toro92]

hi my friend sorry for bother you, but i need your help, i want to restore my toledo mk2 AGR but i need the information of your maxspeedingrods rods, can you give me the information or link for buying it, thx an sorry for bother you! good job bro!

[@Ajme-kb4os]

Where did you get all your specs? I’m trying to rebuild an alh before I put it in my 4Runner and feel lost.

[@austinniemela]

The Bentley manual is huge!! Get one!

[@Ajme-kb4os]

@@austinniemela awesome, thank you so much for the reply! On an old video no less. I’ll go get me one for sure

[@austinniemela]

@@Ajme-kb4os no problem! I wouldn’t attempt the rebuild without one!

[@Gumbile]

What hapens if you put a measure down of the head gasket? Woul you get valve damage or just a bump in compression?

[@austinniemela]

Most likely both!

[@Gumbile]

@@austinniemela Hm i was wondering puting a measure down on my own PD 130 1.9 TDI to increase Compresion guess its not a good ideia?

[@austinniemela]

@@Gumbile I wouldn’t, if you want more power do a tune or a turbo

[@Gumbile]

​@@austinniemela I have 2056vk garret turbo and a IC with custom pipes i was junt wondering if it was possible

[@kennypowers4330]

For your next build you should try and source out a better machine shop and maybe they would sponsor your videos or something... kinda made me mad when I saw they wrote different measurements than what they were, regardless of being in spec! Nice video series! You and your brother are rad!

[@austinniemela]

Thank you!! A good machine shop is hard to find these days!!

[@JEREMY120983]

Alive soon! 👍😎

[@mikefixel3238]

Do you have a recommendation for a machine shop in our area?

[@austinniemela]

I use American machine! They seem to be pretty good

[@mikefixel3238]

@@austinniemela Do you use them for the heads too?

[@stevewhyte8476]

that bore deal pisses me off . i cannot get any satisfaction from paying people "professionals" to do anything either . seldom anyway . good thing you checked . really enjoy your videos .

[@TimberTramp]

I wonder what it takes to get a hilux diesel....can they be had in Mexico or South America? I had a friend that worked at Toyota and somehow he got a factory yota diesel and swapped....why Toyota won’t offer a diesel in the states is beyond me!

[@austinniemela]

You can import them!

[@dobermann2013]

Hi Austin, I am very thankful for your great videos. I gave to machine shop my brm block (2006 jetta tdi). However the machinist did not ask me for cylinder head bolts which tells me he does not have torque plate to simulate the cylinder distortion. I noticed your block was machined with a torque plate which is perfect. My question is: How much this plate makes difference when you measured? Thank you, and have a great day!!

[@austinniemela]

It makes quite a difference! When i pulled the torque plate off it went out of round a bit, cant remember how much now! Hit up FranksTDI. Tell him i sent you he will hook you up with a plate

[@b13nissan]

Passat bhw has oil spray jets.

[@bonza007]

Why did you put a VW engine in a Toyota? Is it more reiable, or easier to work on, or more powerful or ???

[@jimmadonna1436]

Nice work! I never let anyone work on my stuff. If I mess it up its on me and me alone. I want to write to you can I send you mail care of Devin or Cameron?

[@austinniemela]

Jim Madonna absolutely!

[@jprock73]

👍

[@ieatflys]

what pistons are you running?

[@austinniemela]

ASV pistons!

[@ieatflys]

asv? do you have a link? im building an alh for a dd cherokee and fored pistons arent around... how do u like the maxspeed rods? im frightened to use them

[@austinniemela]

@@ieatflys www.cascadegerman.com/product/1-9tdiasv-s-nur/

[@austinniemela]

@@ieatflys I had no issues at all with the rods!

[@ieatflys]

very nice thank you forged im assuming?

[@KamionKing]

how can you trust those maxspeeding rods? as far as i know they’re cheap chinese company

[@austinniemela]

They seem to hold up just fine! 99% of crap you buy anywhere these days is Chinese!

[@KamionKing]

@@austinniemelaof course. i was just wondering because I’ve seen them being used by a lot of people.

[@kodyhuff8147]

Yo is Cameron your brother?

[@fredl1532]

My VW Alh has over 500 000 kilometers

[@Toyotas_n__Tools]

The part where your measuring things out would of been a great time to do a voice over to kinda explain what exactly your doing, i know it can throw you off track filming while doing work. With doing a voice over you can edit your video down and then do the voice over.. Your able to tell us better what your doing after the fact. When are you doing a toolbox tour?

[@jandkwhite6459]

just finished the video and.....well.... shit. Hopefully they get it done right for you soon

[@rkan2]

Related to some Niemelä? :P

[@kfuhs696]

They can buy you a new block

[@stayfree1613]

Gotta bore these engines with a torque plate.

[@MB-mx7vz]

He did.

[@gurjindersingh199]

I want to be half of what you are one day bro

[@melvinsmutters7662]

Hello?

[@eurobeatmachinist732]

you need to buy some machining equipment, so you can do your own machining