AAZ in a Samurai

[RunninWild]

Hey guys. I've been thinking of some questions on my build recently and rather then make a new thread constantly I figured I'd just start one and update it over time as I think of stuff.

I'm still in the parts gathering stage, with the intent to have the engine built and do the swap by the end of spring. I'd like to get somewhere between 130-150hp and 150-200lbs of torque with useable power from around 2500rpm to 4500rpm. No idea how much boost (+/-20lbs?) I'd need to get there or If I'd need a giles build on my stock aaz pump? Anyways please keep this in mind with some of my questions

build will be 2.5" high flow exhaust from downpipe with no cat
possibly use my stock samurai airbox if its not too constrictive
smaller/medium sized dual pass intercooler
New OEM AAZ Head
Freshly rebuild AAZ bottom end
AAZ pump (giles tune in future?)
VW Garret T3 (holset in future?)
boost/oil temp/pressure gauge/egt gauge
Fairly small geared suzuki samurai with 31" tires I'll be around 107km/h at 3000rpm. I'd think the motor would have more then enough torque down low for offroading as I'm currently running a 1.3 with 76 ft-lbs (when new) and don't have too many problems getting around with it at the moment. I'm looking for more power on the highway and around town and especially for the bigger tires I'll be running.

First thing that comes to mind is:

How important is an external oil cooler? When I google AAZ oil cooler it comes up with this fitting for the filter housing

I assume this is just an in/out for an external cooler? Is it in any way temperature controlled similar to a thermostat?
How big of an oil cooler is necessary if it is at all? I've got limited space to mount an intercooler and oil cooler, and eventually a power steering cooler infront of the rad, and I'd ideally like as big an intercooler as possible.

2nd question: Do I need a power steering bracket/pump from an AAZ or will a 1.6td or even a tdi (unlikely) bolt on and not interfere with my alternator or injection pump?

3rd question: I recently bought a 2nd hand AAZ injection pump, it looks to be fairly clean and in good shape. No obvious signs of any previous leaks. Previous owner had never attempted to run it, just bought as a backup from a wrecker then decided to sell it. Is it worth putting in a seal kit? Are these pumps fairly durable? Should I trust its alright for the build so I'm not stranded when I get it all put together?

4th question: I've managed to acquire 11 injectors (4AAZ + 7 1.6td) with no idea on their condition. Can I mix and match them when the time comes to get the engine running if the majority of them end up doa?

[golfmk1tdr]

THAT IS NOT FITTING FOR EXTERNAL OIL COOLER! It IS THE OIL COOLER! You connect water coolant hoses to that outlets. It cools oil with engine coolant when hot and also warms oil on cold starts in winter (diesel needs long time to heat engine oil to working temperature, that is why oil-water coolant is best solution for this engine )
If you can, put it on it will be all you ever need on a car with that kind of gearing. Also check oil cooler for leaks when you buy it, even new ones can leak. If you have money you can get bigger oil-to-water cooler from modern TDI engines, but I think that would be overkill for what you need, oil will never get that hot while offroading (and if it does you just back of a bit, right?  )

2. 1.6 td steering pump can be fitted to the engine, but first check if there is enaugh room in engine bay, I am not familliar with samurais (but I do have suzuki swift 4x4 gti waiting in the shed  ) If there is no room you will probalby be making you own brackets. ( I think there was engine conversion kit for these conversions, check the web)

3.  If pump was standing for long time pump vanes can sieze. It's easy to change the pump on the car if you can get to it (again I dont know samurai)
I would try it on car first, if it works you can tune it at home to about 130 hp.
If you take it to ordinary pump mechanic I he will probably try to rip you off, atleast that's my experience with them...
If you have cash just send it to Giles, that way jou can be sure for reliability and power (and he is fair guy)
I would rebiuld it alone if I had to do it again, I am superpissed with the shop that did mine (they couldn't even do GOV mod and didn't bother to ask me if they should replace worn out piston, $&%$ 


4. Every decent diesel shop should be able to test your injectors for cheap, also you can make you own tester from truck jack (dont know the right name)
It's best to just get new original GTD injector inserts, they are not that expensive.
Also naturally check if 1.6 are the same as 1.9 on outside, I don't know for sure as I only did 1.6 head (for now).

EDIT: also be super careful when bolting injectors into head, head can crack easy on injector threads. Hold torque wrench with both hands when you do it.

[RunninWild]

Thanks alot. Thats good to know about the oil cooler, definitely saves room for a bigger intercooler. I dont have one at the minute so TDI is the one of choice?

The samurai engine bay is fairly large, people fit 4.6l V6's into em so I'm pretty sure I'll have room in every direction but up ( i know the hood has a fairly tight clearance with the 1.9). Yes there are kits, the one I'm buying says its alright to use the original power steering bracket and pump I just wasnt sure if the 1.6td was compatible.

I'll look into getting the injectors tested. I did email one shop but they said there only willing to test them before and after they do a rebuild and gave me some over inflated price.

[golfmk1tdr]

http://www.peachparts.com/shopforum/general-information/224334-how-build-diesel-injector-pop-tester.html
If you are DIY inclined consider this.

Also found thread on oil coolers:
http://forums.tdiclub.com/showthread.php?t=78993