It has been a few years since I made this post, I have learnt a lot about VWs and the TDI engine. I have done quite a bit to my car since and I have been very happy with the results.
I am getting better fuel mileage with added power =D
you can follow my build
http://www.instagram.com/MK4mo_TDI
http://www.facebook.com/MK4moTDI
I started out with a 150HP kit from KermaTDI.
Dyno days
I then rebuilt the Engine and started adding more.
Engine & Transmission Upgrades:
ProSport Evo guages
42draftdesign gauge pods
Tune from KermaTDI
CNC Port and polished head w/ ceramic coating
Oversized valves w/ ceramic coating
Frank06 Dual valve springs
Colt Cam Stg 2
Black Nitride cam lifters
ARP headstuds
ARP main caps
BHW oil cooler
PD150 intake manifold
Frank06 Malnar H-beam rods
ARL 0.5 over w/ ceramic coating
Goetze Diamond Coated rings
Frank06 High volume Oil jets
BRM oil pump (23 tooth sprocket)
Bosio DLC 764 Nozzles (for now)
Borg Warner S7 Turbo (for now)
Braided stainless oil supply
3bar map
11mm FIP
PD lift pump
Kerma FMIC
Kerma OMI
Custom airbox intake snorkel
Kerma CCV
ProVent 200 Oil separator
Nicktane fuel filter cap
EGR & Cooler delete
Custom stainless 2.5" turbo back
SB stg 2 Endurance clutch
Wavetrac LSD Front & Rear
Sigma 6 Speed short shifter
I am now almost done a full 4motion swap from a 02 Bora PD130.
4motion swap:
Picture from Chris Korwan with Korwerks LLC who supplied the 4motion swap.
Euro 02 Bora PD130 4motion Donor
6speed 02M, Haldex & drivetrain
Fuel Tank, Lift pump & 2x sending units
Floor board (rear seats back)
Dutchbuild Haldex Controller
Im also adding new Brakes & Suspension to help with the extra power and weight added.
Brembo 17z 6 piston 330mm front brakes from a VW Touareg
R32/TT spindles
R32/TT control arms
R32/TT Rear 256mm rear brakes
RotorLab Custom cross drilled rotors