Well its all gone pete tong!!

[Mozza]

So after a long discussion last night with a friend of mine I think the head gasket has gone or the head has cracked, so Mid september the jetta will be coming off the road to use the money that i would have spent keeping it on the road to fix it,

So my question is, If the head has to come off, and im going to put a new one on,

What alterations should i make to get a comfortable 140BHP from it,

I will put a new head on it and arp bolts, the rover 420 boost pin, and sprinter nozzels, also making my ic a front mount,

But i what to know the decisive shopping list ie what turbo, manifold, size ic, etc, so i can work out a cost!

Cheers for all your help and wish me luck as im dammed if im going to give up on this car now!!!

[gnavs]

Sounds exactly like my situation, simple headgasket change turns into a top to bottom rebuild with "go fast" parts 

From what I've read and experienced, Garrett T3 turbo, PD150 intake (you're in England so they should be cheaper/easier to find than the one I got) and a 2.5-3" exhaust.  Definitely look at porting your head and manifolds while you're at it.  The Rover pin is also a great addition.   And if you're feeling spendy send your pump to Giles! 
Of course, some gauges to monitor all this extra activity and you should be near your goal.

[Smokey Eddy]

there is an ebay seller selling EMUSA intercoolers for VERY cheap and they are well made. I'm on my second one (because i crashed the first one) and its a great size and easy to deal with. I got the 27x8x3 i think. RadoTD can confirm as he got the same one as me.
If you're trying to do this with a 1.6td i would get the AAZ head & valves. If you already have the AAZ head you can totally re-use the valve train and cam shaft. no need to replace those as they are fairly high ticket items. Granted of course they are not damaged or worn.
to expand no what gnavs said, you want oil pressure, boost, egt, and maybe oil temp.

ps. love that movie!!!

[Mozza]

What movie is that?

I am currently running a complete aaz, with a 2.15 straight through system, standard 1.6 td ic and a performance air filter,

[Smokey Eddy]

the movie is called "It's all gone pete tong"

Port the head to kingdom come. Spend hours doing it. PD intake is the best! the stock K03 turbo is tiny and not really good for the application you are wanting. T3 may even be a touch small but worth a shot. You'll need a rebuilt one that will  boost to 28 pounds comfortably. Did you look up EMUSA on ebay? they are like $70...
for best results you should get Giles to make you a custom pump but that will add over a thousand dollars to your cost... which i think is insane (however, he is in canada so if you wait for the sterling to come back up it would be worth it for you). I value my entire car at just over $2,500... the pump alone being $1000 of that i think is crazy. but it makes results. all the best builds have one. its the heart of the engine.
I would get an oil pan baffle. ARP rod bolts & main bolts. you might be okay with the 2.15"... you may need to make it shorter though or go bigger to 2.5" or even 3". You'll need to upgrade your clutch if you want to push 140 without breaking things. a 210mm flywheel, clutch & pressure plate. Have the flywheel lightened. search "lightened flywheel" on the forum.
you may also want to look into changing out the stock half axles. my build broke my oem ones.
run your intake to the rain tray with a big cone filter on it. that will help with spooling and also its a great place to draw air from. and heck, if its raining you may even get some nice humid air in there for cooler EGTs.

[honda_is_the_best]

lightened flywheels are not all that good of an idea on diesels. makes them vibrate more at idle. they are smoother with normal, or heavy weight flywheels..

[Mozza]

cheers for all the advice guys, its a great help,

the giles fuel pump is something i would love but cant afford at all, as for running the air filter in the water tray, what would you cover it with to stop to much water being sucked in, I can see how it would be a good cool place to put it though,

[Patrick]

Took 4 pounds off the flywheel on my AAZ, next one I do will lose more pounds. Don't knock it until you try it!

[AudiVWguy]

The flywheel on mine is 8lbs. No idle issues, with less weight for the engine to rotate, the motor accelerates noticeably faster.
Consider water/meth injection. Works well on diesels.
Cheers,
-JB

[Mozza]

How does water/methol injection work, sorry for being a noob

[gnavs]

Essentially it's chemical intercooling.  There are a few good writeups and DIY suggestions out there, this one being the one that stood out.  I've seriously debated fabbing together a homemade kit, really doesn't sound too difficult at all.
http://www.turbomirage.com/water.html

[honda_is_the_best]

Took 4 pounds off the flywheel on my AAZ, next one I do will lose more pounds. Don't knock it until you try it!

i have tried it. i took the diesel FW off, and put a gasser FW on, and it lost alot of bottom end, but gained a little top end. i dont think it was worth it tho. idled rougher too..

[Syncroincity]

Don't worry about water if you go to the drip tray with the intake, a little water is a good thing. (see water/meth above) It's when you have a low-mounted "cold air" intake that gets completely submerged in a puddle that the engine turns into a wet-vac and bends all your rods.

It will be very loud in the cabin, however... the sound carries right through your HVAC.

[Mozza]

Cool it sounds like a good plan, and i aint worried about loud,

I have been looking on ebay and can get a NEW Head for £180 with a 24month unlimited milage waranty to boot,

Let the rebuild commence!!!

[Smokey Eddy]

Nice deal on the head.
No one minds a little turbo wine in the vents eh eh eh
until it drives you crazy.
honda_is_the_best, is it annoying having it there?