MK3 AAZ questions

[veector]

Hey guys I am looking to upgrade my MK3 AAZ Jetta for some extra power.  (un)Luckily my pump is leaking in a few places so thats going off to giles with the injectors,  going to have it built for 25psi but dial it back to 15/18 for now.  More like 15 max with the anemic KO3 thats on there now haha.

A bit of background on it,  I deleted the eco stuff on it (egr type thing that limits boost at lower rpm, installed a 1.6TD boost pin, converted crankcase recirc to a dump, 2.5" turbo back exhaust) I have a boost gauge and pyrometer on the shelf and will be installing both with this new setup. 

Now my question is will a OEM MK3 TDI intercooler setup be enough to keep the EGTs down or will the plastic end caps just blow off on my first pull?  Maybe use a MK4 intercooler if its bigger/ stronger. 

I am also thinking of swapping in a k24 that i'd have rebuilt before putting in, old technology but they are cheap.  Is there anything that would work just as well if not better for around the same money?   

I did a bit of searching around here but only found a bit of info,  either I suck at search or it sucks hahaha

Cheers

Vic

[RabbitJockey]

i think the mk3 intercooler is enough for the amount of air a k03 or k24 makes

[vanbcguy]

The stock Mk3 TDI IC will be fine around 15-18 PSI, not sure how it will fare at 25 PSI.

K24 would be a reasonable upgrade on an AAZ... yeah, it's old school but so is the K03 that's on there now.  It will definitely be happier at 15PSI+ than a K03 would be.

[RunninWild]

Any intercoolers you would suggest for high boost vanbcguy?

[vanbcguy]

Anything made out of welded aluminum will be fine. On my Mk3 I did an AWIC (air water intercooler) and mounted the intercooler rad where the AC condenser would have been. I don't think there's too many direct fit options for the stock TDI IC location off the shelf, if any.

Sent from my XT1097 using Tapatalk

[veector]

Thanks for the info vanbcguy I will definitely keep it at 15/18 for now and when im ready prob go awic and throw some head bolts in there down the road. 

[Dubdoc]

I have that setup on my AAZ in a Rabbit pickup. I used a Garrett T3 from a 1.6, Giles pump and injectors, big downpipe and a 2.25" exhaust with a large Magnaflow muffler. I'm presently running 20psi every day and couldn't be happier. For an intercooler, get a Saab Blackstone cooler. They're cheap and good.

[Dubdoc]

Oh, don't forget ARP head studs !