KW-Systems P-Box with ALH Engine and Age-Related Issues

Dear forum,

I'm facing the decision of whether to install a powerbox from KW-Systems (www.kw-systems.de) in my ALH TDI. Manufactured in 1998, with 128,000 km (approximately 79,000 miles) on the odometer, and driven 85% on highways.

I could get the box for a quarter of the new price, and it's in good condition. A friend of mine now has a PD TDI and no longer needs it; he used it for 70,000 kilometers.

I'm just wondering how big the risk is that something might happen to the engine.
If you read the reviews on the KW website, it seems like this box is quite good.

I'm not entirely comfortable with 10Cent Tuning because it can't be officially registered. Otherwise, it's certainly a cheaper alternative to a tuning box.
'Tuning the car's engine is no longer an option, in my opinion, because it has already been driven for too long.' I could disassemble the box later and resell it.


I'm just not sure about the wear and tear (ALH engine).
The car's speedometer reads 195 km/h, and it goes a bit faster going downhill.
I'm not exactly sure how many Nm and PS it actually has now (no reliable testing facility available), and I don't know anyone who has a VAG Com (to unlock the GRA function).

I haven't had the car for that long yet. It's running much better now than it was before. I removed and cleaned the AGR valve and deactivated it, then I added a diesel system cleaner. Before this, I properly cleaned the LMM (mass airflow sensor) and repaired the hose that goes to the air filter box (it was drawing in warm air because it wasn't properly assembled and a clip was broken - I've fixed everything).
But, in reality, the car with the 90 hp ALH TDI engine and the 16-inch VW wheels (size 205) should, according to the speedometer, be able to reach approximately 205 km/h.
The only thing I might be able to do is to inspect the LLK (likely referring to a liquid cooling system) more closely - I'm hearing a faint hissing sound coming from it, as if air is escaping. And that can't be a good thing, right?


I would be grateful for any tips.

Hi.

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I am facing the decision of whether to install a powerbox from KW-Systems (www.kw-systems.de) in my ALH TDI. Manufactured in 1998, with 128,000 km (approximately 79,000 miles) on the odometer, and driven 85% on highways. I'm just wondering how big the risk is that something might happen to the engine. If you read the test reports on the KW website, it seems that this box is quite good.

No one can tell you that for sure; it always depends on the specific operating conditions.
A motor that was consistently run at full throttle, even when cold, might fail prematurely, potentially even within your current mileage.
Generally, with such high mileage, it's advisable to have the injectors checked beforehand, as faulty injectors, especially when combined with tuning modifications, can significantly increase the risk of damage.

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Chipping is no longer an option for that car, in my opinion, because it has already been driven too much. I could take the box apart again later and -.

And so what? If the car has already been lowered too much for the chip, then it's definitely too low for a lowering kit as well.

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But, actually, the car with the 90hp ALH TDI engine and the 205 size 16-inch VW wheels should, according to the speedometer, be able to reach approximately 205 km/h.

As long as you don't specify what kind of car it is and you withhold information about the complete set of standard and optional tires, no one can offer a well-informed comment.

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The only thing I might still be able to do is to inspect the LLK more closely - I hear a faint hissing sound in the stand, as if air is escaping. And that can't be a good thing, right?

If it becomes significantly louder (with hissing or whistling sounds) when the charger is engaged, there is likely a leak between the charger and the engine. It doesn't necessarily have to be located on the LLK (likely referring to a specific area or building).

Hi Uli, thanks for the response so far. Okay, bitte gib mir den Text, den du übersetzt haben möchtest.

So, the previous owner wasn't a reckless driver (we've known him for a long time), and I think he treated the car normally. And full-throttle, high-octane driving isn't really his thing (I sometimes indulge in that myself, but not for very long because the fuel consumption increases too much - I mostly want to drive economically).


Can you not notice a change in the spraying pattern? 'How much would such an inspection cost? (I think I read somewhere that it's very important to make sure the injectors are okay before tuning).'


I meant that chipping isn't worth it because I can get the box cheaply (and I could still resell it later) -
'Those chips would probably cost around 500-800 euros, and they would be gone if I sell the car.' 'Also, it's also too expensive for me. Would it make a difference to increase the boost pressure from 890 mbar to, say, 1 bar if you've installed a turbocharger upgrade?'


Car: First registration 04/98, ALH 90hp engine, Highline trim with winter and electric package, 4 doors, no additional spoilers or side skirts, standard tires 205/55 R16 V on VW Montreal rims.


No, it doesn't only get louder when the charging cable is plugged in. You can already faintly hear the hissing sound when the vehicle is stationary. If you kneel in front of the vehicle (where the onboard charger is located), you can hear it more clearly. However, I'm not sure if it's a hissing sound or just the normal noise of a bearing.

I hope that with this information, people can now do more with it.

Alex.

Hi.

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Doesn't one notice a change in the spraying pattern? How much would such an inspection cost? (I think I read here that it's very important that the injectors are okay before tuning).

Since the wear and tear is gradual, it's likely only noticeable when the system is switched back to its normal operating state – for example, when new nozzles are installed.

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Does it make a difference to increase the boost pressure from 890mbar to, for example, 1 bar when you have installed a turbocharger box?

Performance-wise, usually not. It only "helps" if the engine is already producing a lot of soot, and you want to reduce that soot. Then the performance is usually already set so high that you should be more concerned about its lifespan...

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Car: First registration 04/98, ALH 90hp, Highline trim with winter and electric package, 4 doors, no additional spoilers or side skirts, standard tires 205/55 R16 V on VW-Montreal rims.

Aha... quite a few unnecessary data points, but I still don't know what type it is .

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No, it doesn't only get louder when the charging system is in use. You can already faintly hear the hissing sound when it's stationary. If you kneel in front of the vehicle (where the LLK is), you can hear it better. I'm not sure if it's a hissing sound or the normal noise of a bearing.

To be sure, pressurize the piping system between the turbocharger and the intake manifold (disconnect it, seal the ends, and then pump it up). If it's still hissing, you'll know where the leak is.

Sorry Ulf, I thought you wanted all the details that could potentially affect the final speed, hence all the details.
It's a Golf IV, don't ask me why I didn't write it, probably because I only frequented Golf IV forums and didn't think about it .

Okay, isolate the piping system and pressurize it. But how am I supposed to inflate it? (I haven't really looked into that in detail yet.)

I don't have any experience with P-boxes yet. Is KW a 'useful' brand? I've read something about being able to turn it on and off with a remote control (but that's not included). However, I would prefer a wired connection and then route everything through the free switch (an ESP or ASR switch that I don't have yet).

'By the way, the manual states that the box is adjustable.'

Thank you for the answers .

Alex.

DerAlex wrote:

It's a Golf IV, don't ask me why I didn't write it, probably because I only frequented Golf IV forums and didn't think about it

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Okay... if he's using 205-profile tires, wanting a speedometer reading of 205 km/h for a 90 horsepower engine might be a bit ambitious. I think a speedometer reading of 195 km/h would be more realistic (assuming no wind and no downhill slope).

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Clamp the pipe system and pressurize it, okay. But how am I supposed to inflate it (I haven't really looked into that in detail yet

Insert wooden discs into the rubber pieces and seal them with the clamps. Install a bicycle valve into a wooden disc (previously), through which the tubing system will be inflated.
If you hear hissing sounds coming from somewhere other than the wooden boards, you have leaks there.
(As far as I know, the idea came from Rainer.)

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I just don't have any experience with P-boxes yet. Is KW something that's "useful"? I've read something about turning it on and off with a remote control (but that's not included). I would, however, prefer a cable connection and then run everything through the free switch (an ESP or ASR switch that I don't have yet)

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I would also prefer a cable switch. I'm not sure if the KW-Box offers such an option.

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Also, another thing, the box is adjustable, as stated in the installation instructions.

Then don't be tempted to only want power... that has already ruined many engines.
Let's say the increase in performance, as measured by the dynamometer test (before-and-after comparison), is around 20%. Apparently, the machines don't immediately fail just because of that.

Then I should be satisfied with 195 km/h, and I have to assume that other TDI drivers have been falsely advertised with a speed of 10 km/h more.


The box can be switched on remotely, but I can add that feature later if needed.

I wanted to drive the car in a sensible way because I was worried about the wear and tear on the engine and other components.

Possibly, chip tuning might be a better option.

Okay, but how do I know the power output now and in the future?
Unfortunately, I don't know of any testing facilities in this area, and I have no idea how much it would cost. I also don't know how much the inspection of the injectors would be.
Can anyone provide some information about this? I'm from the Rhine-Ruhr area, specifically the Lower Rhine region (around Duisburg, Mülheim, Krefeld, Moers, etc.). If anyone has any tips, please share them .