Thanks for in input everyone. This is a "mock" setup. The intake is made by Spearco, an aluminum part from an aftermarket turbo kit for the NA 1.6 diesel. The exhaust manifold is very similar to the stock cast gasser type made to accept the turbo. The exhaust is crimp bend restrictive. My goal is to upgrade the components around the pump. I will not push the engine to the limits.
did you port the intake to match the tdi D style ports? how is the fueling limited at 4k if you have an m pump? there is much to be gained above 4k especially if you have good flowing parts. tdi can handle up to 6k as long as the flow is there and the pump is tuned properly.
I didn't match the intake to the block, i'll check that out. I wanted the rev limiter set @4k. Im sure more power can be made above that mark.
I have a pro cleaned PD150 facing if needed
I have to face left on my install
Kool, I'll google pics to see what one looks like
What do you have holding the head down (arp studs, etc.?) ? I would assume at that amount of boost you will most definitely have the head gasket as a weak link. Also I agree with what was said about the flow of that turbo and the high egts. Without looking into it I think it is safe to assume that you are pushing it far outside of the map. If you were to add water methanol injection with the current setup I think it is safe to say that might cause more harm then good with slightly increased cylinder pressure which you are already pushing pretty hard. Or the possibilty that slight boost in power could help you over spool that turbo for the last time.
With a larger turbo though the water methanol injection with proper setup can help you spool slightly quicker so you wont notice much difference in spool time. Although my home brew setup in my truck was only hooked up for a short period of time it was a serious boost of power when it engaged (boost referenced on) that helped me light my turbo. Then this will also help get the egt's down to a point where you are going to want to ditch that rev limit.