I figure if the engine is too far gone I at least have a usable trans, and shouldn't the trans work just as well for a TDI? There shouldn't really be any difference trans wise between the two types of engine.
And as far as horsepower, 100hp (+ some change, I think it was 102 or 103 hp actually) sound right for a 1996 IDI engine?
Depends on your trans code. Find it on the bell housing of your transmission. Go to this site:
http://zelek.com/diagram_charts/diagramlist.htmGo through that list and determine your trans' gear ratios. Once you have that, go here:
http://www.scirocco.org/gears/Input your current tire size into the fields provided. If you want to find your cruising speed, use your 5th gear ratio and specify your desired speed.
The trans will work with a TDI, but revs might be a little higher than a comparable TDI since the IDI's tend to be a little more efficient near the midrange. The only way to find out for sure is to determine your trans code.
And 8vOF is close; stock AAZ power figures are 75 HP @ 4500 RPM and 114 ft.lbs. at 2500 RPM. The ABA 2.0 gas motor is the only thing i can think of coming close to 100HP stock, and they only had 90-94 HP stock.
The AAZ is a solid engine minus crank concerns, and will serve you reliably in you Jetta. Adding an intercooler, installing larger diameter exhaust system from the downpipe back, and modifying your fuel injection pump and boost levels can and will see you beyond 100HP on the stock internals. I'd pick up head studs if you plan on going added power, to be on the safe side.
That's NOT knocking the awesomeness of a M-TDI AZU/1Z, but you've got yourself a solid base already, if the head and pistons haven't done too much damage to themselves. Do what R.O.R. and burn_your_money say, and dissemble the engine, fixing the crank sprocket concern as well as refurbing the valves/pistons if necessary.
Sorry for the long-winded take on things, just had a lot of thoughts on this.
Good luck!