Golf 1991 GTD 1.6 - MORE POWER?

[k7aus]

Hi i'm new to all this GTD appreciation and just getting into it all. I have a 1991 Mk 2 Golf GTD 80BHP with slant engine intercooler 250k miles. Im after more reliable grunt, i do have a mercedes sprinter intercooler but need some advice or plumbing it in or someone who can supply the necessary boost hoses or pipework, i'v been told that this mod will release e few more BHP but does anyone have any other cheap mod suggestions. Bearing in mind that this car is my daily driver and needs to be ultra reliable.

Cheers [/i][/i]

[malone]

Moved to IDI forum from the FAQ forum.

By only installing an intercooler you will not see significant gains because your engine is already running "lean." To make the intercooler upgrade worthwhile you'll also want to turn up fueling a little by adjusting your fuel pump's screw. Diesel power is primarily based on fueling.

The following threads have instructions on boost & fuel adjustments:
http://vwdiesel.net/phpBB/viewtopic.php?t=645
http://vwdiesel.net/phpBB/viewtopic.php?t=579 (1.9TD, but the tuning is very similar, and this thread is probably easier to follow through).

Rule of thumb if you don't have an EGT (exhaust gas temperature) gauge; do not increase fueling to the point where you emit more than light exhaust smoke. If you're smoking, don't sustain WOT under high load (towing or highway speeding) that way.