2006 TDi boost ?s

[Obnox]

Hi, I have a 2006 TDI (1.9) Jetta/Bora, manual.

Can I use a manual boost controller (a la Turbosmart)?   Boost gauge (autometer) is in.  What boost should I be seeing, stock?  Stock (injectors, intercooler, fuel pump, turbo, exhaust/downpipe), what is the max boost I can go to safely?

Bang for buck, what reliable mods should I do next?

I can get a stock Eagle Talon intercooler or a Greddy medium sized IC core.

Car is a daily driver, want reliability.  Have a sportbike for really good seed adrenaline rushes at track days.  Just want a nice, safe bump up in power and more highway get-up-and-go.

[rallydiesel]

Stock max boost is about 15 psi. A boost controller will cause you to go into limp mode. If you want to run higher boost and fuel you need an ECU flash. Stock intercooler is more than adequate. Best first mod would definitely be an ECU flash from someone like Rocketchip, Kerma, Alligator, etc. Easy way to gain 50 hp. Next would be a clutch upgrade.

[diesel smoke]

Do NOT start running more boost with the stock VNT 15. BAD things happen. Expensive things. Been there, done that. Cost $5K+.

[Obnox]

To clarify:

So the stock VNT 15 Garrett turbo can't handle more than the stock 15 PSI boost?   Sorry, just coming form my old car mod days when we'd jack more boost into the Eagle Talons, stock turbo and all.  Why would that be?  I'm curious.

I'm in Ontario, what places would be best for flashing my ECU?   So a manual boost controller (grainger valve/ramp setup, a la turbosmart) would not be recommended?  Why does it induce limp mode?  (What is that?)

Thanks!

[Vincent Waldon]

I'd recommend you head over to www.tdiclub.com and read read read.  Tons on info on turbo limitations, limp mode, etc.... and there's an Ontario section where you can read about local tuners.

[diesel smoke]

As far as I'm concerned, the VNT 15 is too small for the TDI if you start moding. I got a VNT 17 now and aint looking back. FYI, I broke mt VNT 15 turbo shaft in 3 places...

[rallydiesel]

You can't use a gasser type boost controller because the actuator is controlled by vacuum, not boost pressure. If the ecu detects higher than normal boost pressure, it will go into "limp" mode, which is a failsafe sort of state where engine power is cut drastically.

A lot of people run the basic Rocketchip tunes and similar which increase the max boost to around 18 psi. The fueling is also increased with the ECU flash and you get around 150 hp. If you want more power than that you'll need to go with a larger turbo, like diesel smoke mentioned.