1.6td engine swap

[idi-tracker]

Putting a 84 1.6td into a 97 Geo Tracker 4x4, using the Acme Adapters kit.  Bought the motor complete as a good take out, had a bad piston. Starting the rebuild process and was wondering what should be done or changed.  I like to do things right, and 1 time only, so if it will increase performance and reliability I'm all for it.  If there are better factory parts say from a newer diesel, I would like to know about them.  Any info would be great...  Here is what I'm thinking so far  Bottom end---Stock crank, Stock rods with ARP bolts, Kolbenschmidt  pistons (already purchased, 1st over bore), Arp main studs, factory windage tray/gasket, new oil pump (brand ?), new bearings (brand ?), Total seal rings.  Is it worth rebuilding the 1.6 head or is there something better?

Looking for good low end torque for the trails, but also would like to cruise at 60/65 mph on the highway..  Also looking for engine specs to give to my machinist.

 thanks,
 Scot

[theman53]

The 1.9 aaz head flows better than the 1.6 head because it has much bigger valves. It is a hydro head, so if you have a hydro 1.6 it is a bolt on affair. I don't see the need for total seal rings, I would only get the Goetze rings, but I have heard the Kolbenschmidt rings that come with the pistons are ok too. Just don't get Grant or topline or arco or really anything else. If you have a mech engine and not a hydro you can put a hydro 30mm oil pump in for a bit more oil, if you have a hydro you can put an aaz pump in which is 36mm for even more oil...you can use the 36mm in the mech too. You can use the aaz head on a mech block, but you have to block off the extra oil drain up front. Not a bolt on affair but very possible I have done it with the hydro head on mech block.
If you want good low end and only want good power to 65mph then a small turbo is it for you. The 1.6 either came with a K24 or T3 which are about the same and will work for you if you give it some fuel and a 2.5" exhaust all the way back. You maybe better with a K14 from an aaz or rigging a vnt 15 from a TDI. If you are going to spend money and want a great all around turbo buy a he211w holset and spend the money once. I have around 1,000.00 in my setup and it would be easy to spend that again for another project now that I have the results

[idi-tracker]

Were would one find a aaz head?  and will the 1.6 intake & exhaust bolt up?  I have seen some people mention the "PD" intakes, are they worth finding one? 

[theman53]

The aaz head has D shaped intake ports as opposed to the oval, but the oval can be ported to match. Everything bolts up. The PD intakes are better than stock, but still not a great improvement. If you are skilled at welding aluminum you can make one fairly easily. The PD already have the D shaped ports fwiw

[idi-tracker]

I see a aftermarket aaz head available from Prothe, good or bad?

[sdubfid]

If it' not too late, sell all your idi parts and buy a mk3 tdi swap for $1000.  What size tires are you running?

[idi-tracker]

TDI swap requires a non factory front suspension set up, since the whole engine assembly is taller.

[Diesel_Zuk]

TDI swap requires a non factory front suspension set up, since the whole engine assembly is taller.

It's not that much taller. The block is only 3/4" or so taller if I remember correctly.