1.6NA to TD - Yes common question I know

[Bugsy_malone 666]

So A while back I used to run a 1.6TD in my baywindow van which I broke due to a serpentine belt conversion without one of the clutches on the alternator. Bit of a disaster really as I was running veg oil too!

So anyway before that I had run a 1.6NA with golf GTi downpipe and 2.5" exhaust, which was all very loud and power of a wet fart. That engine was stored (badly) since 2008, until the weekend where I decided I wanted to go diesel again, but thought time for a bit more power.

I had a bit of a read through some of the FAQ regarding this but had a bit of a question relating to the turbo.

its a standard NA block(mechanical lifters), I have a mk4 golf TDi inlet manifold, apparently some variety of Turbo pump a turbo manifold (with worn out turbo) from a mk3 golf 1.9tdi (K03). Oil pump is 30mm.

I planned to clean and paint everything as the bores look clean just light amounts of soot on the top of the pistons, new standard head gasket, light polish and port of the head, and rebuild the block to 'standard'. The fuel pump I was going to strip and get a seal kit for it, look into the governor mod but be conservative about it because this is an NA and only needs a bit more power. Intake side I havent got much choice as the engine is installed like in a vanagon at 50 degrees over meaning space is limited for much else, I dont think a GTi manifold size will fit, the standard Vanagon one didnt which is why I was on the mk4 TDi one.

Then it came to the turbo bit the K03 has a ton of play in it and I am not willing to spend a fortune rebuilding, I have a K24(I think) from an 87 TD, but what I was finding is power came in quite late, could have been a number of things, but I decided from what I read it doesnt reach full potential till late on in the rev range, fine for a car, but in a van I want off the mark towing power if I can. I had a route around and I also found a Garrett T15 turbo which has a tiny amount of shaft play but i think its probably what I'd call serviceable/useable.

I wonder if anyone had any experience with these turbos? It looks like it'll bolt straight onto the K03's manifold (3 bolt flange) and it was from a 1.7TD Vauxhaul/opel engine.

I also have various intercoolers laying about to help out (not sure where I will locate them on the van) but wondered what people might advise to look out for/do as this is going in a camper van not a nice light car!

Also something I dont think I have come across much is flywheels. I have the Vanagon Diesel flywheel, but found I also had a passat one which was similar, but more weighty. I wondered if a heavier flywheel might actually help because its in the van or whether that might cause issues.

Opinions/ideas?