What to do to a stock b4 that needs a turbo?

[99GTsc]

My turbo is shot, so I'll be digging in to replace that soon with a KKK. I want to modify it a bit and would like some recommendations. The car is completely stock...

My "to do" list looks like this:
1. New turbo, KKK 006 003 http://www.industrialinjection.com/
2. New filters
3. Clean out I/C and piping
4. Autometer Z-Series 30/20 Boost Gauge
5. Clean out intake
6. Glow Plugs
7. 2.5" exhaust
8. Bilstein shocks/struts ($230)
9. N75 Valve
10. New crank pulley/dampener
11. Timing Belt parts, Water Pump, v-belt, ps belt

What else should I do while I'm at it?

 

[tomo366]

Forget The KN and save your $55 waste of money........

 

[99GTsc]

"Dont get the K&N" and...

I've seen some of your posts and was hoping someone like yourself would give me some insight here. From what I remember you have a lot of B4 experience...

 

[paramedick]

You won't see much gain from the oversized exhaust. Save your money unless you need the new pipes. You can do a mufflerectomy if you just want a different sound to the car.

 

[Toronto_Vento]

The K&N filter won't give you an performance improvements, and if you over oil it, it'll gum up the MAF sensor, and you'll be replacing that. BTW, ever wonder how K&N gets higher flow? They have bigger holes in the filter media. Not good. Get the OEM filter and save particles from getting into your engine.

As for the muffler upgrade...mufflerectomy seems the way to go, so the cat-backs are kind of a waste of money unless you feel like trying to tune the sound.

What's an N67 valve? Are you talking about the turbo boost controller? N75. If not, what does the N67 control? And if you want to have fun with the turbo, you can go to a proper shop and see if they would be willing to make you a frankenstein turbo. Check out the performance section, but some have built turbos that will fit to the stock components but are rated at a higher boost level.

 

[jck66]

TV, according to the FAQ, we should limit the pressure the engine sees to 18 psig. I think the stock turbo can supply this (at sea level) as those of us who have gone through the N75 replacement issue can attest to.

I wouldn't think anyone would need a different turbo unless he was trying to break his car.

 

[99GTsc]

John
Oops, I meant N75. Thanks...

No I really want to just replace the turbo not upgrade, so a hybrid is out of the question.

John and Bruce
No not a muffler upgrade, or even a cat-back...it needs a complete exhaust system. The downpipe flex section is leaking, the pipe right after the cat has already been repaired once, and the tail pipe is in need of repair as well. I do understand the horsepower level here doesn't warrant 3" pipe but I have some 2.5" and 3" in the garage and was thinking of just using it up. I would have to buy 2" pipe.

I guess I'm looking for more TDI specific suggestions...general maintenance issues not covered in the FAQ. i.e. "You might as well replace the oil fed line to the turbo while you are at it" or “don’t do this you’ll get a CEL”. I really don’t know my way around a diesel engine nor how to tune one properly for added power.

I’m not trying to make this a 100bhp beast

, but just replace what needs replacing. Yeah, I do need an air filter...

 

[fastvicar]

Why not make it a 100bhp beast if you're rebuilding the turbo anyway? Cost difference will be very little.

BTW, I did notice my B4 breathed a fair amount better at the top end after I put a Techtonics Tuning exhaust system on it.

You need a chip. NEED!

 

[paramedick]

Ok, I understand. If you have the larger pipe, why not? Save some money and delete the muffler, unless you have to have one for inspection.

Your plan looks like a good one, except the K&N filter.

There is a roller in the TB path (relay roller, 028109244), replace it. I would also consider a water pump at the same time. Not much money, and a heckuva lot cheaper to change with the TB off.

If you have a squeaky belt when cold, you may want to consider the crank pulley replacement. Improved part corrects this.
AutohauzAZ

 

[99GTsc]

You need a chip. NEED!

Whats that going to get me really? To me thats a slippery slope that I'm trying really hard to stay away from. Don't get me wrong I usually take a header down the "slope" but not on this car. So a chip is $300ish, might as well install injectors at the same time...oh I need VAG-COM now, and a MBC, and then, and then...

But seriously, what does a chip do for me? (I read the FAQ but I want your opinion)

 

[99GTsc]

If I have both manifolds off, the timing belt, and valve cover....should I pop the head off as well? How do the head gaskets hold up on TDIs?

 

[rdkern]

A chip give you more power. Bigger nozzles gives you more power. Potentially less economy (if you use it) and may not be needed. I liked my b4 without the chip, but would have problems going back. Go figure.

Vag-Com is a tool. It is something else. It will help you keep the machine going, and check, usually fix, and clear codes when you get them. I'd go for this without worrying about any slopes other than accumulating tools you'll need for other maintenance. For instance, I got the metalnerd injector wrench, mityvac lookalike, torque wrench, and pela oil extractor, as well as the vagcom. No slope here.... lets see, next will be the injector puller ...

 

[trae]

"Dont get the K&N" and...

I've seen some of your posts and was hoping someone like yourself would give me some insight here. From what I remember you have a lot of B4 experience...

Replace the accessory belt/alternator belt roller I did mine recently it was noisy and dry DG can set you up with one.

DON'T WASTE THE MONEY on a premade exhaust. Mine crapped out last year and by asking around a guy at Car-X turned me on to a shop run by a guy with a tuned Neon who ran a 2 1/2 straight pipe all the way back from the cat and welded on a big ole shiny tip for $150.00, the whole shebang. If I had leaks ahead of the cat he could have probably fabbed something for that for small $$. Or as some have done depending on whether you have to be inspected or not just ditch the cat and run a straight pipe all the way back. If my cat was bad I would have done a 3" pipe but given a smaller pipe running down to the cat my installer felt a 2 1/2 pipe from the cat back was the best compromise. A straight pipe WILL make a small difference on a B4 they are overly restricted stock and no you don't need no stinking mufflers.

If you want to mess with the air filter go with an Amsoil or just stick with the stock filter.

You can get Rocketchips for I believe $175 or not much more which are plug and play and with your stock injectors will have no driveability problems (quite the contrary) and very little smoke problems. Your mileage will be no worse unless you are always getting down on it. Quickest/cheapest/most bulletproof way to get 120hp and you can always plug the old chips back in (yeah right). Jeff at Rocketchips will need to know if you have a BK or GQ ECU and can answer any other questions you may have. If this is the only power mod you do and all others relate to airflow and maintenance you don't have to worry about a thing. There is no need to replace your injectors unless they are worn out and for power/diveability alone a chip is a lot cheaper.

Stuff that has busted on my B4s that I would replace "while you're at it"--plastic upper shift cable bracket; if this breaks which they can after a few years your shifter will feel like a paint stirrer you will likely only be able to find 2 gears

Relay 109 if you still have the old black one they tend to start cutting out due to heat when they get older get the gray one so you don't get stranded

Probably the N75 also otherwise when it goes your car will all of a sudden feel sluggish over 90-95mph.

 

[Diesel Dude]

On the TDI's you do not need a boost gusge that shows vaccuum, as there is none of consequence. Go with a straight boost only guage of at least 25 lb range. This way you get more sweep on the guage face that is useable for a TDI. My $.02

 

[99GTsc]

Thanks for the tips guys.

I'm talking to Jeff from www.rocketchips.com about getting a stage III chip as well.