I installed a window in my 2.0 CR tdi block this morning via a lazy connecting rod... Needless to say, I did a little searching this morning for some TDI replacements. First, there is 1 (ONE) 2009-2015 5th letter "L" OEM long block left on the shelf in the entire VW parts network (World-wide). It is sitting in NJ and will continue to sit there for a price of $6,500....
So, I did a little more research and found a whole market full of used 2009+ motors (2009+ is important as that begins the CR - Common Rail - motor). You can have them anywhere from $1,200-$2,600USD depending on the mileage. I have selected a 2010 model year with 50k on the odometer for $2,400 including shipping to my door. This does not include turbo, ECU, wiring harness...just a long block.
Now, that motor makes 140bhp/239fp stock as advertised (133 whp) with a DSG transmission. Malone ECU tune and a DSG software upgrade with a DPF and EGR delete will get you north of 220hp. Software related expense is only an additional $1200. Since your application is off-road/racing I would simply go with a straight 3" pipe although there is some details about a high-flow cat that may be useful.
The turbo is so small in this thing (impeller is about the same diameter as a quarter!) that without a little backpressure it is subject to over-revving the turbo. Not sure that is a huge problem on a race application but on a daily driver it isn't so good. They say the high-flow cat is enough to prevent it, perhaps a little creating plumbing can be done without the cat to generate the same results.
That said, I am not spending money to go back to stock. I may not do the DPF/EGR delete because of the expense of replacing the exhaust components (new plumbing sans the DPF - $1,400 additional) but I am seriously considering the $1200 for the tuning. That still gets a 140bhp to 200bhp which will make replacing a motor at only 80k a reasonable justification.
If you are looking for performance on a TDI, check out Malone Tuning, they are about the biggest player in the game. They have distributors all over the US and their work is highly recommended from what I have seen. I may have more details to share in the coming weeks about that...we'll see.
(FYI, there is a long story as to why the rod failed at only 80k that has to do with a dealer moron tech and a failed turbo...not worth the lengthy whining rant here
)
FYI - That second one listed above on ebay includes the turbo. It is a factory installed Borg-Warner that will retail new at $1000. That actually doesn't look like a bad deal.