I spent a solid couple of weeks obsessing about what direction I wanted to go in for my wagon/variant build, to the point that it was keeping me up at night. I realized it would make most sense to flesh out my ideas here and seek advice from you all.
This is a long-ish post, so here's my brief abstract: Should I upgrade my 1.6 NA? Build up a TD motor? Or drop in an AAZ? I'm stuck!
So anyway, I rebuilt my 1.6 NA 9 years ago and have put around 50k miles on it. It's strong and perky but has been a little neglected since I bought my Sprinter (i've also noticed harder starts and lower top highway speeds). Since I've been putting all this time into aesthetic upgrades, I figure it's time to rethink the heart of my beast. I'd love to have a little more power and maybe increased MPGs. Also should note that I'd love to reinstall an AC system. I deleted my AC belt configuration and have been happy with the worry-free belt setup so I know what I'll be dealing with if I follow through with AC. Not a huge issue but still part of my thought process.
Anyway, here are the three options I have to work with:
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Option 1: Upgraded 1.6 NA ★
Same motor, with head studs, Giles pump, new head gasket, etc.
- Check valve clearance and adjust shims as needed. Verify compression in all cylinders.
- I have a hydraulic block mated to a mechanical lifter head. The extra oil drain in the block was tapped/plugged but I plugged the water jacket hole in the head with JB weld.
I know. While I haven't seen any huge issues, there is some weepage. So, I was considering pulling the head and having a shop tig the hole.
- Install ARP head studs and upgraded head gasket (that's a thing right?).
- Install
Giles performance IP (procured from a friend who never ended up installing it and is selling it cheap).
Associated costs: Giles IP - $500?, head studs - $200, head welding: $100? Total - ~ $1000
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Option 2: Convert 1.6 to TD ★
Running junk yard motor upgraded with turbo setup
- Build up a secondary running motor pulled from a junk yard.
- Solid lifter ME block with a head that ends with a D, which I understand was used for the TD engines. I'll be running a compression test this weekend to see if it needs full teardown.
- I have all the components I need to do a full TD build, including a K14 turbo and a k24 turbo. I've been looking into both options and understand the risks and advantages of both running on this engine.
- I would install oil pressure/temp gauges and a pyro gauge to make sure I don't wreck an engine not meant for these pressures.
- I can buy a $75 TD IP core from someone to have rebuilt, so I would be getting the most of the TD build (boost enrichment, etc)
Associated costs: Engine/Tranny pulled and TD parts - Close to $1000 ¯\_(ツ)_/¯, Additional costs (head studs, gaskets, bigger exhaust) $1000 to ∞
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Option 3: Swap to AAZ ★
AAZ engine shipped from Canada, mated to 020 AOP trans.
- This option was presented to me on FB when I was going through turbo ideas a while back ago. Seeing as how I had no leads on reasonably priced AAZ engines or cars, I didn't really think too hard on it. But I was connected to a guy named Andrew Moore who runs CanadianCatalyst.com and he said he had 5 running AAZ engines in his inventory. He would sell one for $1400 (with shipping). I have no reason not to trust this nice man, but if anyone else is familiar with him or his company I'd love some feedback!
- Obviously this could potentially be a no-brainer swap if I chose to go this route. Better power, better belt system, and with potentially no engine tear down or rebuild involved (fingers crossed). If it's as perfect an option as I believe it could be, then there's really not a lot more to it than dropping it in and running it. Also, since I'm interested in adding AC, I'd have a better belt system and would just need to see if the Mk2 components matched up with the Mk3 compressor.
- The only downside is a very minimal one -- I spent so much time and money researching TD builds and collecting parts that it would be a shame to just abandon that route! Or it just means I put the parts to use on a new car build
Associated costs: Shipped AAZ Engine: $1400, upgraded exhaust - ??