Awesome £150 map is a flash and go, no dyno time.
Firstly Get rid of the panel filter.
They do not improve performance at all and filter far less, danging the turbo blades 100%. The stock intake and OE paper filter is by far the best solution and has absolutely no problems with handling more power than the engine internals can handle.
The £150 remaps are very gentle as they are flash and go and as they're from a large company like Awesome they are very safe.. they boost around 15-16psi and produce basically no smoke so the fuelling is not that much more.
I'd estimate around 135bhp from being in my friends car who got done recently. It's a lovely smooth map but there is more to give. You can run 17-18psi safely on these turbos (as I ran mine from 103k till 143k on at 18 psi).
Fitting ASZ (PD130 same ias the 150) injectors is a waste of money WITHOUT fitting a larger turbo.
ASZ injectors flow (I think from memory, I can't remember) about 35% more fuel than the PD105 stock injectors.
Therefore on the same map, at the same fuel request level the car with PD130 injectors would be fuelling 35% more.. what does this mean? TERRIBLE smoke and I mean it's dreadful. This is all wasted unburnt fuel and is not good for your car as it will clog up the VNT mechanism very quickly.
You can't just whack more fuel in a diesel you need to whack more air in as well and the stock turbo is a bottleneck as it cannot produce enough airflow/boost to even out the air to fuel ratio.. While you CAN have PD130 injectors fitted and mapped I would personally WAIT until you have a turbo capable of running those injectors. Finding someone other than Darkside to map it would be a challenge and Darkside even say they would recommend not fitting larger injectors on a stock turbo car.. And neither do I having done it... (I only did it as my injectors got fitted for free).
You will get no more than 150 GENUINE BHP on a stock turbo and stock injectors.
With PD130 injectors and your turbo literally at bursting point (19-20 psi so right on the limit of the stock MAP sensor) you can edge 170bhp. Your turbo will need to be at bursting point to have a driveable car as you can't just inject less fuel as the spray patten becomes so poor it will not fuel correctly.
EGR deletes do not really improve BHP they just ensure it remains consistent by not recirculating hot (dirty) exhaust gas back into the intake.. It's more for clean running and reduction of soot more than anything..
If you want to fit PD130 injectors you will NEED to fit a larger turbo, at the very least a GT1749 or even better a 3rd gen VNT unit like a GTb1756. I had a 1756 on my old TDI.
If you do this then you will need to upgrade the suspension and brakes (brake upgrade requires a hub transplant as you can't change the brakes on a 1.9 TDI as the carriers and hubs are one piece.
You'd need to then ensure all your suspension bushes etc are in tact as trust me when you get the full whack of a big turbo TDI it will be hairy.
Your clutch will pretty much explode if you try to take more than 160bhp through it so you will need a SMF conversion kit with upgraded pressure plate and clutch disc.. you will also want to ideally swap out to an S3 intercooler and hard pipework kit or at the very least fit a hard pipework kit with clamps/jubilee rather than the crappy VW fitting.. (hence why hard pipework kits are good, only Darkside produce these for the 1.9 Mk5 engine).
Hub upgrade to 2.0 TDI/GT/GTI hubs - £150 inc labour est
R32 brakes at least really (£250+ labour)
PD130 injectors - £150 ish
INJECTOR SEAL KIT (you MUST replace these) £85 for all 4 (+ fitting as it's pretty tricky to time them all up again).
Turbo - around £800 give or take
Clutch and flywheel - £600+fitting (let's say £200) darkside supply a custom machined flywheel to take a G60/VR6 clutch on the 1.9 5&6 speed boxes..
Suspension, overall, coilovers/dampers/bushes etc (£600 inc labour)
Hard pipework kit - £350
S3 intercooler - Around £200 if you can find one)
EGR delete - around £80
Mapping - only place to do this sort of stuff is Darkside so around £400.
Darksides budget turbo kit with a GTB1756vk is £1850+ vat so more like £2300 and as mentioned you will need a clutch, injectors etc.
