1995 Jetta 2.0L Turbo

This is another one of Reflex Tuning's cars. This turbo project was built last December 2006. The exhaust, downpipe, intercooler piping, and exhaust manifold were all hand built. Along with the turbo kit we also swaped in an 16v Passat 02A transmission, after finding out that the stock 020 clutch was slipping on a mere 5 lbs of boost.

Our goal with this build was to make a car that you can jump in, turn the key, and drive it everyday. Looks were also very important. We kept the intercooler hidden behind the bumper and make the intercooler piping as neat as possible.

The car is currently running on stock compression and saftley running 11lbs of boost. On a Dyno Dynamics dyno it hit 169whp and 201hp at the crank.

This car is going under the knife again this winter...when it is done it will have 12 more valves and a lot more power :-) Stay tuned for more updates.


Engine Specs:
OBD1 2.0
02A trans with VR shift tower
Turbonetics T3 Super 60
C2 chip
42# injectors
2.5" exhaust to VR6 muffler
2.5" downpipe
FMIC with 2.5" piping
Joe P Inline boost controller
mk4 DV

The Build:

First priority was to open up the exhaust to a 2.5" from the turbo back using the
stock VR6 muffler.





We decided to flip the stock manifold upside down and build an adapter for the turbo.




All tacked up

Downpipe tacked together

Welded up

Test fit

Intercooler piping tacked together

Doug cutting the rebar to fit the intercooler

Intercooler test fit
In order to have the intercooler sit behind the bumper we moved the radiator back about
an inch or so.

Doug tig welding the intercooler piping together

Oil lines we made out of Aeroquip hose and fitting

Tapped oil pan

Finished product