ALH Engine, simple mods to get circa 150bhp?

[jonnyb]

Hi folks, After some messing around, i finally identified my engine as an ALH.   I believe these are fairly good to mod, but im finding mixed messages on the forums. 

From what i gather, uprated nozzles and a remap can make significant gains? 

Just hoping someone out there could provide a little more info?

[EsSeX dAn]

on my one (asv 110hp non pd)130 turbo, red turbo pipe, 1.8t pancake pipe, uprated side mount intercooler, 57mm boost hoses that ive custom done so no boost leaks from the stupid vw clip in hoses, .216 bosch injector nozzles, a blacksmoke home remap and a big bore downpipe with decat.oh and an egr delete the map quotes 137hp but im guessing it has more due to the other upgrades. you could put a pd150 turbo on or a hybrid, get an 11mm fuel pump and get a proper remap from r-tek or similar rather than a generic one to get more ho

[jonnyb]

I was looking into the larger injector nozzles (although not sure what size is necessary).  And definitely a remap.  Is the decat really worth it?  I work in an exhaust factory, so may be able to get something doen in the development workshop to save the pennies

[EsSeX dAn]

i personally think the decat is worth doing. theres less turbo lag (not that theres a massive amount anyway) turbo spools up quicker and slightly more whooshy sounding. to do it cheap ive heard of a few people just smashing the cat to bits inside its box and pouring out the innards.
the injectir nozzles youll want will be .216 size ones. a remap will be the biggest gain youll get really, with my blacksmoke one it made a world of difference! its quick, keeps up with the high power rx8's, beats civic type r's fiesta st focus st170's and other cars of similar spec

[jonnyb]

I think its settled then .216 nozzles and a remap for now.  If im honest, i dont want to go down the route of serious bhp, just a little more than 90.  After a GT Tdi Mk5 140bhp, the 90 is too much of a step down.

Roughly what should the nozzles and remap take the hp to?

[EsSeX dAn]

a remap will take you to about 110/120hp and the torque will mych improved. i think on your one the big limiting factor will be the turbo. i cant remember if your turbo has the vnt mechanism but if it does, youd be able to put a gt1749v on which is a 110hp turbo and a straight swap.
but injectors and remap will be a nice jump for now

[EsSeX dAn]

another thing thats cheap and easy is an egr delete, get the plates off ebay for about 5squids, this also helps with the whole inlet manifold and egr valve inlet goo'ing up. also take the manifold off and give it a good mr muscling! makes it run a bit smoother etc

[jonnyb]

I have been looking at the EGR delete, wasnt sure whether a full Allard style delete was needed, or just the blanking plates.

Where i work, I could probably get an allard kit made up (we makes exhausts day in day out).

From TdiClub ALH means 90hp A4-style engine with Garrett VNT-15 turbocharger and Bosch MAF.
So im guessing i could upgrade to the garrett turbo you suggested?

[EsSeX dAn]

yeah man the turbo from a 110/115 will be a straight fit with regards to boost hoses and what not.
you could make an egr urself, use the flange from the existing egr and weld a straight pipe to it. the blank plates would probably be just as quick and easy.