hi isneil,
An AAZ would help your acceleration i have an AAZ in one of my campers and a 1.6 d with no turbo in another camper, when i drive my camper with the AAZ its great up hills and accelerates like a car but i am still only cruising at 65mph on the motorway because the gearbox really could also do with being upgraded.
There lies your second problem. Once you have changed your engine you are going to be faced with a gear ratio issue..... £££
AAZ can be found in golfs and similar of around 1994/5 you are looking at a MK3. It is not quite a straight swap, there is lots of info on the wiki,
The AAZ engine runs quite hot, when mine was done the cooling system was renewed, and this keeps it cool nicely, tunning can be carried out on this engine but further cooling is reccomended for any tunning as it will run hotter.
Idealy a gearbox rebuild with taller ratios or a taller final drive. There is a gearbox guru on here who is master of gearbox rebuilds, Aiden he deals with all those issues,
How fast do you want to go ?? the 2.1 petrol does about 95mph, but i bet it drinks juice doing it, my AAZ wil do about 35mpg at about 65mph.
If you want to spend more money you can go down the TDI route, you will deffo need a gearbox for these engines tho, figure around a grand maybe a touch more for a gearbox from german ebay , about 350 - 600 quid for the tdi engine (example maybe a 1z) and a whole lot of trickery with spanners and electrics for a decent mechanic, and quite a large labour chagre, again nothin that hasnt been done on here by baxter or spannerboy to name a couple and probably many others.
If you have loads of money and dont mind blowing it you can make a T25 go fast, there is a rover V8 one for sale at the mo, sure that goes quite well, pleanty of subaru's allready done for sale from time to time, maybe cheaper to sell your 1.6td and buy one ready made ?
All depends what you want to spend. My 1.6d with no turbo is slow and steady it cruises at 55 on the motorway (but is capable of about 63) and climbs big hills in 2nd gear at 20mph, I love it.
