Help Me Spec-Out My 1Z Build?

[rich brennick]

I'm in "information-overload" from all of the great opinions I've read here and at tdiclub...
What I have:
1996 Passat 1Z TDI 1.9 w/ K03 Turbo/ 5 speed approx. 180,000 miles;  started and ran well before being
disassembled down to the short block- bores look nice.
Has a "BK" ECU
General maintenance to do:
     -Have my automotive machine shop check the block/ crank
     -Mains/rods/ intermediate shaft bearings
     -Piston rings after a hone if the bores are in spec.
        Stock rings or Total Seal to keep blow by in check?
     -Check head/ replace cam and followers, seals, etc.
     -EGR block off
     -Intake cleaning- done

My application for this drivetrain will require as much reliable torque at the low end for moving a "heavier-than-stock Passat" vehicle at freeway speeds and with all that I have read, the engine certainly has the capability to produce some awesome torque with available upgrades such as:
     -A chip What brand to choose?  I understand the "BK" ECU is not the greatest for tuning?  Another type code would be better and a direct swap?
     -Nozzles  What size/ brand to choose?
     -Larger exhaust diameter (I can do that)
     -Different turbo or is my K03 good for my low end power requirements?
     -Is my stock TDI pump up to the task for my application?
     -A larger intercooler? I'd have the room for it if it really helps...
     - I also plan to upgrade the clutch to VR6 specs.

Anything else come to mind?
And I will thank you all ahead of time for helping me figure out what's best for my application!
Regards,
Rich
     -

[jtanguay]

go with total seal.  i bought the goetz rings and they modified them for me with their total seal rings.  egr delete is a good idea because you won't need to clean your intake again without it.  as for turbo, the k03 will give you good low end boost, but if you can afford it, go with a VNT turbo.   for intercoolers, bigger is better, but put it in an area that has good airflow.

probably wouldn't hurt to go with some new bearings, and polish up your crank.  maybe even a very light hone?  total seal also has their quickseat stuff.  from what i hear it works great so try it out!  (helps seat the rings much quicker)

[rich brennick]

Good info,; thanks.  So you buy the stock piston rings- then send them to Total Seal?

OK, how about a chip and nozzle combination?
Different types/brands of nozzles- .205 to .216??
Different chip companies- any opinions/

Rich B

[MikkiJayne]

You can buy the rings as a complete set from Total Seal too, rather than buying Goetze rings and having them modified. The part number for the TDI rings on the Total Seal web site is a complete set.

[jtanguay]

You can buy the rings as a complete set from Total Seal too, rather than buying Goetze rings and having them modified. The part number for the TDI rings on the Total Seal web site is a complete set.

they said they couldn't make as good rings as the stock goetz rings... read the post from hillfolk'r