1.9 AAZ build, am I missing anything?

[Buji88]

Hey all!

I hope everyone is staying safe during these crazy-ass times. I'm wanting to run an idea past all of since everything I've learned about the IDIs have pretty much been from this forum.

Anyways, I put a 1.9 AAZ into a Suzuki sidekick, and its been great, but it's underpowered so I've decided to build my dream AAZ. I've included a list of the mods I plan to make. My goal is for it to be simple and reliable and have 90 - 100 HP.

-AHU crank and timing gear (to help eliminate any potential crank nose issues)
-1.9 AAZ injection pump with a 1.6 TD pump top (simpler)
-1.6 GTD injectors (being able to rebuild/tune in my shop)
-Whichever injectors lines fit better (heard super mixed review on this)
-VR6 oil cooler (maybe Passat one if I can fit it)
-T25 flange manifold
-Probably HE211WG turbo, although it seems it's possible to run the VNT 15 fairly easily (looking into this now, if someone has links Id love to see)
-PD150 intake.

Am I missing anything, any other mods you can think of I should look into doing?

[libbydiesel]

Intercooler. 

[Buji88]

True, left it off the list, already have!

[libbydiesel]

If you are using the stock AAZ serpentine belt system and alternator, then you should definitely install the AHU clutched alternator pulley onto the alt.   

[Buji88]

That is the driving force going to the AHU crank and timing gear because I'm currently running a GM CS 130 alternator with a solid pulley and I plan on going to a CS 144 because it's going to get a winch and dual batteries. With that being said I'm running the belt without a tensioner but the new plan is run the VW style tensioner on the alternator and doing the same for the water pump and power steering pump as well.

[libbydiesel]

The AHU crank/sprocket will fail with a serp belt and solid pulley on the alt.  It is as simple as that.  It is not unheard of for the AHU crank/sprocket to fail also and I suspect that those cases are caused by the alt pulley seizing so it is no longer spins openly the one direction. 

[Buji88]

Good to know, I will be switching that over to a clutched alternator then, it seems like there are tons of options on the GM cases which I need for my build.

[libbydiesel]

There are a decent assortment of clutched sprockets that can update alts with solid sprockets.  You might not need to swap alts and just get an appropriate pulley instead.