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Engine Specific Info and Questions => IDI Engine => Topic started by: 2west on December 28, 2007, 10:02:23 am
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Hi everyone!
I'm very happy to have found this forum, I'm sure you'll be able to help me a lot into my current projet. I did not buy anything yet so I'm making the budget before. And I know more you have info BEFORE beginning better it ends.
I'm gonna swap a VW 1.9TD (AAZ) into a Toyota 4runner 92-95. It has already been done so I'm not too afraid.
The first step for me is to rebuild a AAZ from A to Z :wink: and while I'm gonna been at there I'm gonna tweak some little things to make the engine ready to output more power from it as I expect to need a little more from the engine. (expecting about 130-140hp maybe more if it's easy, not too much expensive and reliable) To be honnest I don't know how much power a AAZ can output safely but it's where I wanna go.
I'm not at my first rebuild but I'm new to diesel. I'm sure I'm gonna be ok with that but I will need your help to do the right the first time.
Here what I wanna do to the engine and parts I will need infos about:
- Complete rebuild engine kit including oversized pistons, bearings, timming blet kit (which kit should I buy and from which place)?
What is the maximum bore that can be done safely to these engine?
- Stage 1 head porting: port match and deburring only
- Bigger injector nozzle (which size should I buy and from who?)
- Brand new glow plugs (thinking to buy those on e-bay) It's very cold here in winter.
- Custom intercooler
- A new seal kit for the fuel pump
- Rebuild kit for turbo.
- Complete engine gasket set... also, where should I buy.
Afterthat I'm gonna swap the engine and work step by step to tune it perfectly. One of my friend have the air/fuel analyser so we will set and fine tune the blend perfectly when I will acheive the right power output.
Thanks a lot for your help. I'm gonna be glad to post picture when I'm gonna start the whole thing.
Any comment or advise will be GREATLY appreciate :)
Etienne :)
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- Bigger injector nozzle (which size should I buy and from who?) merc 617 nozzles from bosch and 1.6 injectors
- Brand new glow plugs (thinking to buy those on e-bay) It's very cold here in winter. dont buy from ebay, unless they are bosch, i bort sum cheap ones and snapped the ends off them in 2 weeks.
- Custom intercooler ebay, but you get what you pay for
- A new seal kit for the fuel pump probly from vw but i wudnt bother
- Rebuild kit for turbo. you dont need to do this they last forever, i sugest upgrading to a t3 if you want more power
- Complete engine gasket set... also, where should I buy gsf if you have one where you are
hope that helps, also if you dont already know, aazs self destruct.
i didnt believe it until mine did, u need a clutched alternator and a crankshaft and pully off a tdi, i used a 1z
if you dont bother or think it wont happen to you, your pully will shear off and ull have to start again with a new head and block