MWVDUB said:
Specifically, I am looking for an air intake system, a new chip and some exhaust. If anyone has suggestions, please let me know.
Hi MWVDUB,
Welcome to TDIclub! I suggest reading the TDIFAQ document (click on FAQ link at top of page). The TDIFAQ document has a ton of useful TDI information including a section on power upgrades.
Re: Air intake system...you're probably thinking about a K&N filter and adding a cold air intake. Stick to the OEM paper filter and don't bother with a CAI because VWs already have a cold air intake system. The stock airbox system is already designed to way outflow the engine, so there's virtually zero benefit to try to improve it. Also, K&N filters have destroyed a lot of Mass Airflow Sensors (MAF) due to contamination because K&N filters are known to not filter as well as the stock paper filter does. K&N filters are best described as MAF eaters and engine sanders and result in zero HP gains = BAD. Stick to using only the OEM paper air filter and leave the airbox alone. Also, never open the airbox to check the filter unless you plan to replace the filter with a new one. The rubber seal around the filter element can only make a reliable air-tight seal only ONCE.
Re: Chipping. Yes, definitely go for some chip tuning! I have Rocketchip (stage 3) and love it. Check out RC's website at
http://www.rocketchip.com. There are several levels of tuning available, depending on how far you want to go and what other upgrades you have.
Also consider an injector nozzle upgrade. When you read about people talking about bigger injectors, they're talking about bigger injector nozzles. The injector bodies don't get replaced, just the nozzle on the end of each injector gets replaced with a nozzle with bigger orifices ("holes"). This results in more fuel being injected and the ECU knows nothing about the bigger holes. Check out KERMA's website for nozzles:
http://www.kermatdi.com.
With chip tuning and nozzle upgrades, plan on a clutch upgrade because the increased torque will be enough to easily over-torque the stock clutch and make it slip when you get on the power.
Re: Exhaust upgrade. Don't bother unless you're planning enough modding to get your TDI up into the 130+ HP and 250+ ft-lbs range. The stock exhaust is already free-flowing enough as is for stock performance and mild power upgrades. Bang for the buck is virtually zero as there are virtually zero HP gains. The advantages are faster turbo spool-up and lower turbo exhaust gas temps (EGTs) but virtually zero power gains. The EGTs become a concern primarily for heavily modded TDIs. No need to worry about EGTs for stock performance and mild power upgrades.
Chip tuning and a nozzle upgrade will give the best bang for the buck in terms of power upgrades. If you have manual transmission, definitely plan on a clutch upgrade! If you do chipping alone and the stock clutch is still in good shape, then it MIGHT be OK. If you do a nozzle upgrade alone, the stock clutch MIGHT be OK. No guarantees. However, chip tuning plus a nozzle upgrade almost always equals a clutch upgrade!
Modding is a slippery slope...you get a power upgrade and eventually you'll want more!
Good luck and congrats on your TDI purchase.