A few oddball questions.

Hi all,i've been a 110TDI Passat B5 owner for some time,used to run a VW/Audi specialist dismantling yard,and have a general knowledge of the various models/engines.
Now I have a new project.
Its a Mk 1 (A1) Scirocco,I plan to TDI it,however heres the awkward bit,i've allready bought an engine thats been played with,its a UK spec,90 bhp 1Z code tdi,its relatively low miles so i'm told,and has been running in another vehicle with the following:
VNT17 turbo,as fitted I believe to the UK spec PD150 GTTDI Golf,this was bought new by the previous owner,uprated injectors,not sure what these are,but I know they were bought in from the states,and the PO says he understands they were from a 150bhp model,so i'm assuming they are 0.216mm T4 injectors.Next is the pump,Not sure if anyone on here can help as its not a TDI pump,its a mechanical pump from an AAZ code 75bhp 1.9TD,with the boost diaphragm from a 1.6TD fitted.Not sure why.
It all runs,so i'm told,i've took a bit of a gamble to be honest,the PO says hes been tinkering around with boost pressure,by adjusting some plunger on the pump,and with a gauge says hes been playing up to 2.0 BAR,now forgive me if i'm wrong but that 28PSI if i'm not wrong,and based on what I've read in the FAQs on here thats well OTT.
To be honest i'm in a bit deep,I'd like a shed load of power to go chasing Audis with on my 100 mile commute,(yes really)The Scirocco will be very light,compared to A4 chassis cars,and i'm interested to hear others thoughts on any aspect of this conversion,ie boost pressure,exhaust design,even suitable gearboxes,I know I can fit any of the 020,or 02A-J families,but experience tells me that the cable change boxes are much stronger.So what ratios,off the shelf I could use a box from any of the following,1.6TD,1.9TD,1.9TDI,1.8 SPI,1.8MPI,2.0MPI,1.8 G60 and 2.0l 16V. Anyone got any opinions which I should plump for in a lightweight streetracer.
I look forward to hearing some comments.
Cheers Beelzibus.
And yes this is posted in 101, then I figured perhaps this is a better place.

To be honest I would have gone with a TDI 150,
with a chip alone i've seen ppl get 200hp on that motor, and 250-300 is not unheard of.

As for gearboxes, again the best would be the 6 speed variant which comes with the TDI 150, which I have fitted in a Mk2 seat ibiza (which is very very similar to a mk2 golf), but you do have to cut a little of the floorpan round the gearlever housing, but nothing too crazy.
if you want a 5 speed I'd go for the 02J, the gearbox itself is strong, BUT invest in a quaife (or similar) diff as the stock diff is hopeless.

as for boost limits, i've heard ppl running between 1.8 and 2 bar on a 90 hp

I run 1.4 bar with absolutly no problems (as yet) but I will be getting a large turbo very soon as the VNT15 is prone to breaking up at high boost.

The only possible advantage we may have in malta is that with no motorways and no way to sustain continuous high speed (high engine loads)there is minimal stress on turbos.

it's not uncomon to see ppl running 2-2.5 bar on a T3 with no trouble.

well thanks very much for that,with no cash or time restraints I would go for a PD150,with all its electrics,ECU and then chip it,but to buy a donor,then do all the crossover work,big in time and money.
I've had this motor at an absolute steal,A good used 1Z is worth about £400 here,the new turbo costs about £500,plus the injectors,plus all the time the PO has spent converting the engine,And it will drop into the early scirocco very very easily,and the electrics will be a doddle.It owes me £165 in Total,INC the new Turbo.This is extreme low budget hot rodding.
Interesting what you say about the VNT17 taking 2 Bar boost relatively safely,thats good news,ample performance for me i'm sure.
As for gearboxes,Again the 6 speed would be nice,but costly,(approx £400)I can source any stock cable change 5 speed for under £100,Except the 2l 16V box from the ABF code cars,these are a bit pricier,stronger but pricier,but my question is what stock ratios are going to be best for me in a lightweight car.And i'm after acceleration and mid range rather than top speed.And i'm afraid budget constraints mean Quaiffe diffs and the like are way out of the question,although I agree that would be nice.
Thanks again,Andy.

I'd go for a mk 3/passet cable change g/box from a diesel, i'm running that in a mk 2 golf runing a DBW 110 mk 4 engine
more suited to motorway crusing @ 80 Mph(120@4700 RPM in 5th)

the specs on that engine sound fimimar, did you get it from the north west??

Thanks for that Crispy,i've been thinking a TDI box from a Golf might have a slightly different ratio to the Passat,due to the vehicle lighter overall weight,maybe thats the one to go for? Definately disscounted all the Petrol boxes,all rev too high.
The motor came from a guy called Andy,whos in Doncaster.It was fitted in a splitscreen VW pickup.