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    Turbo choice???

    I would buy a cheap 2nd hand turbo, mock it up on the engine, see if it fits well and make all adjustments then-if you’re happy with it- pull it off the car and rebuild it properly ! You cam get billet compressors to fit almost all known turbos, search kinugawa on eBay and send them an email-...
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    Turbo choice???

    You have been advised several times on what turbos will/may work on your particular model, all you have to do is try and see if you’re happy with the outcome ! That’s the way to learn… get an mk3 tdi turbocharger fitted on the car, the AHU turbo is mounted the same way, however with the right...
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    Turbo choice???

    They are cheap as chips in Europe…plenty breaking !
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    Turbo choice???

    I think your best bet would be to use the turbo setup from a mk2 gtd, it has a top mounted intercooler and the pump has already been set by factory to compensate for the boost ! These gtd engines can do over 100 Bhp with a little fettle of the pump governor screw !
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    Turbo choice???

    The OP is really beating round the bush with this post, it’s been advised already on several instances on what might work well on his project, if he doesn’t consider using the suggestions then why the clutter on the thread ? There is no magic to be found from any wastegate turbos on his...
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    What head studs do I need?

    Get pd150 ARL head studs and cut them to length, use your old washers from used head studs but you need to enlarge the holes slightly ! Frankly you don’t really need ARP headstuds with your specs…
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    AHF 110 Project

    Best go for pd115 AJM rods/AWX pistons if your budget cannot stretch to aftermarket forged rods…
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    Weakest internal???

    Do what you have to do mate, set your goal high enough and fight till you get there ! Power is addictive and you soon get used to it hence spending money once, right is the way to go ! Get the bigger nozzles you can afford, the newest turbo you can find and fit in there and spend a good chunk of...
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    Weakest internal???

    The fun is in the modding, when a car works well after you finished modding it you kinda get bored and look for the next project in line to work on ! Sometimes the next project comes before you get rid of the previous and you end up with 2 Project cars, then 3 and so on ! As you grow older you...
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    Weakest internal???

    Don’t we all start this way ? It doesn’t make financial sense to modify a engine built with economy in mind but we all like to tart up our cars with go fast bits even if they add zero benefits to the whole recipe ! Making a car cheap, fast and reliable is a bit of a dark art in this day and age...
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    B5.5 Power Upgrade!!

    Best to find a bv43a turbo and to change the chra from it into the bv43 off the pd housings…better trim, better spool and you get a billet compressor wheel with extended tip technology and 1 extra blade compared to the pd turbo !
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    B5.5 Power Upgrade!!

    Look in the above posts for part numbers…
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    B5.5 Power Upgrade!!

    https://nemosautoworks.com/home/756-kkk-borgwarner-bv43-turbocharger-for-20-tdi-audi-a4-b7.html
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    B5.5 Power Upgrade!!

    https://www.darksidedevelopments.co.uk/products/kkk-borgwarner-bv43-turbocharger-for-2-0-tdi-audi-a4-b7.html
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    B5.5 Power Upgrade!!

    You need bv43 off the 170 Bhp Audi A4/a6 with the BRD engine, it has a vacuum controlled actuator with a position sensor which you don’t use ! Slight work to stretch the outlet hose to go onto the turbo spout but that’s easy to do…
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    1.6 idi turbo build? pictures & specs turbo help needed

    Actually VE tdi will run on peanut butter and will do over 60mpg...
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    B5.5 Power Upgrade!!

    get a bv43, plug and play...
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    Exhaust

    Use a reduced to mate to your existing exhaust system or build it from scratch!
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    A cornucopia of bag things AHU related

    If you’re stuck for an injector puller then go to your local scrappy and find a injector pipe that fits on your injector(take a spare out and try) and weld it to a slide hammer. I have an inexpensive sliding hammer that costs about a tenner on Amazon, it’s meant for Bosch/Lucas tdi injectors…...
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    1.6 idi turbo build? pictures & specs turbo help needed

    I would stop pissing in the wind and just get an engine swap to a 1.9 tdi, AHU, ALE or AFN/ALH if you can with the 5 speed 02M gearbox, you will need a few mounts and a mk3 donor wiring loom but it will be so worth it in the long run ! That kit while it’s huge for yesterday standards it’s a...
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