Originally posted by NewToyo:
Look for a higher volume fuel pump and injectors as well. It is hard to lean out a diesel motor, so the more fuel you push in, the more power.
With respect to the 1.6TD, that doesn't seem to be needed. At least I haven't read of anyone needing to do that. The standard pump and injectors are good enough, AFAIK. In fact, I _think_ they use the same injectors and pump in the 1.9TD, too.
One guy on the Audi/VW Diesel list gets around 100 hp from his 1.6TD. He did the exhaust, boosted the pressure, gave the head a valve job, and installed an intercooler. You should have room for an intercooler. There are some sites that suggest which vehicles would be intercooler donors.
Installing a pyrometer is a very good idea so you don't melt your pistons while figuring out your turbo boost and injection pump adjustments.
...lars
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