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I barrowed my friends stock 2003 jetta and while changing the oil on it (part of the deal) noticed the size of the intercooler is a joke and the intake air piping is pathetic.
At one point where the intake pipe squeezes between the tire and the body on the passanger side, I bet the cross section of that pipe is maybe 2 inches tall and an inch to 3/4 inches wide. Diesel intakes and exhausts need to be big and free flowing, to improve both power and fuel economy.
Now you could put too much intercooler on and over cool the air going into the engine during winter if it gets real cold, but that can easily be fixed with duct tape or cardboard.
I was assuming you were going to replace the intercooler and intake piping? But then I didn't see it listed any where on your planed mods.
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1984 chevy suburban, custom made 6.5L diesel turbocharged with a Garrett T76 and Holset HE351VE, 22:1 compression 13psi of intercooled boost.
1989 firebird mostly stock. Aside from the 6-speed manual trans, corvette gen 5 front brakes, 1LE drive shaft, 4th Gen disc brake fbody rear end.
2011 leaf SL, white, portable 240v CHAdeMO, trailer hitch, new batt as of 2014.
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