You might wanna look for a car with bigger engine, unfortunately the 1.6Tdi has been designed with economy in mind not performance so it's very little headroom left in that engine... I would keep is stock if i were you, seen a few rods bent only from a tuning box ! The small on the rods does not even have bronze bushings anymore, even the old 1Z engine was better built 20 years ago !
I've remapped a fair few of these now and all going strong, it all depends on who maps it and how its mapped. People these days just increase all the maps 10% and think they are mapping the car good.
Pretty sure any modification is going to cripple your insurance at that age. I'd hazard a guess that a 2.0TDI as standard will be far cheaper to insure than a 1.6TDI with a power gaining modification....
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