Hello Ranchero, thanks for your interest.
The bellhousing: After thinking about it, I'm pretty sure it's an SAE #5, 8 bolts.
It has the starter facing "forward" on the exhaust side of the engine. The normal alh bellhousing has the starter facing aft towards the tranny.
The flywheel is doubled, with the original flywheel (without the ringear and the centre cut out) adding weight to what I remember as being a vw Fox flywheel. As I
recall, the fox flywheel has the proper offset for the teeth to meet the starter in it's "forward" position. John, at pathfinder (you can still find him on ebay selling pathfinder parts), can elaborate on this. The lighter flywheel would likely
work fine without the old one added for weight, but that weight will make the engine run more smoothly. I think the combo weighed about 25 lbs.
The starter is from "hi torque". It's basically a VW fox starter layout, (they build new, and do a beautiful job of it) but I had them "clock" the starter solenoid by about 20 degrees to give more clearance from the engine block, otherwise it's jammed to the block. It would
work as original, with a little grinding work, but the alh has more girth than the Fox engine, and I didn't like the looks of it. I believe they saved the configuration for me, so it shouldn't be too hard to order one.
Engine exhaust is from a 1.6l vw pathfinder. The 1.6 was an idi, so there'll be no problem with
cooling the 1.9 ALH since it's a Direct Injection engine and runs cooler.
water pump">Raw water pump is the one used on the
Volvo v8 engines, with a "half cam" installed (puts out half the water of "normal" for the pump) about 8 gal a minute. It's a crank mounted
pump, so the install is fairly easily done. I got a machine shop to make new hub to fit my crankshaft.
Cooling block at the back of the
head: You'll want to make a new "block" to accommodate the water manifold (that
steel tube with all the outlets) going to the
water pump,
oil filter and such. The new block ( I call it that because it's just a block of
aluminum drilled and tapped with npt fittings, and bolted to the back of the head) just makes things more neat, without so many plugs, and over length
coolant hoses. The block changes the angles of the inlets to go around the vac pump and to the
heat exchanger mounted under the exhaust, and you can eliminate some of the outlets.
The injection pump, as you know, is electrically controlled. Gyles at Performance Diesel Injection, is well known in the TDI
forums. He cleverly converted my pumps to mecanical control, and also converted them to be used on SDI engines, which are "non turbo" and put out 60 hp. I got him to match the torque curve of the industrial SDI engines, which I thought would be most appropriate for our needs.
Transmission: I'm using the zf25, which is hydraulic, but the mechanical one would work fine. You could go smaller, but this one is "work duty" for this engine, so should last the life of the engine. I bought mine from Simplicity marine in Fla. They also sell the adapter/mounting plate, and the damper plate. I had to cut 8mm from the end of the input shaft, or you could install a spacer in between the adapter plate and the bellhousing.
To use turbos on these engines would be a little more complicated, but you could mount the turbo at the end of the pathfinder exhaust manifold without too much issue. Now if you're looking for 140 hp, I'm not going to comment on the suitability of any of the stuff I've used, except the starter, you'll be good there.
Engine mounts are custom at the front of the engine, I'm sure you can figure something out there, or use the original mount and build a gantry bracket to the boat. The back mounts are on the bellhousing.
Alternator is original, but the belt is custom order (shorter than normal) and just runs from the damper to the
alternator with the tensioner in-between. I also had the
regulator removed and wired the alternator to a
Balmar regulator.
I cut the bracket for the air
compressor off to make room for my engine beds, but you could accommodate the
compressor if you wanted to.
That should cover most of it. Good luck.
You can contact me via e-mail at my username, using the gmail server.
Cheers.
Paul.