TDI Upgrade: VW Vento 90 PS to 110 PS

hello,
I'm currently trying to decide whether to install a 110 hp TDII engine instead of my current 90 hp TDI. I'd like to know what parts I would need to replace or change, and whether the process is complicated. If anyone has a rough estimate of the costs involved in the conversion, I would appreciate it.
Sure, here's the translation:

'Thank you.'
map

Hi.

...than you might think.

Unfortunately, I no longer have the link, but maybe someone here knows what I'm talking about.
A description of the various small and large problems and setbacks encountered while converting an Audi 80 (presumably) from a 90hp engine to the 110hp AFN engine. For example, the turbocharger mounting was different, and overall, more things didn't fit together than worked without requiring complicated modifications.

I think it was an Austrian website...

My tip: Get the original 90s model and have it tuned to 110 horsepower with a switchable tuning option.

My current car already has a chip installed. Since the chip from the 110 HP model also fits, that's not a bad option. My goal is to achieve approximately 140 HP with the chip.

Hello,
As far as I know, it's not that difficult to install the 110 horsepower engine in a Golf/Vento if it already had the 90 horsepower diesel engine.
I know of 3 cars where this was done.
The difficulty lies in finding a suitable donor car (for the engine swap), as the axles also need to be replaced (due to the brakes). The final cost depends on how much you can sell the old engine and parts for. I think it's too much effort overall; it's better to sell the old car and look for a new, more powerful one.

Albrecht.

If you can find a motor with an axle, the job will be done in 6 hours. You can reuse the 1Z wiring harness; it also fits the AFN engine. However, if you're installing climate control, it's more work, and you'll need to remove the wiring harness as well.

But otherwise:

- disconnect all cables.
- Drain the water.
- Vorderachse abschrauben (incl. (Shock absorbers)
- Karosse hoch. Engine out.

Einbau umgekehrt. Auspuff neu oder anschweissen, da der 1Z um 2 mm kleiner ist als der AFN. Ready.

I paid 2300 EUR for that AFN with 80,000 kilometers on the odometer and climate control.

Why does the entire axis need to be replaced?

Replacing the brake calipers is enough. It's a change from 256x13 to 256x20.


2. I wouldn't weld anything to the exhaust pipe, as the entire design is different. Diameter: 1Z = 50 mm / AFN = 55 mm.
In addition, the intermediate silencer is larger.


3. Kabelbaum behalten ??? Sure?

The 1Z engine has a boost pressure control valve, which is not present in the AFN engine. Additionally, the 1Z engine has an air hose that connects to the engine control unit (ECU) for pressure measurement, whereas the AFN engine does not. In the AFN engine, the pressure is measured outside of the ECU.

There's nothing to change on the front brakes; even the 90 horsepower models already have internal ventilated discs, which are 256x20mm. However, the rear axle of the 110 horsepower model has disc brakes, unlike the 90 horsepower model, so the axle problem might be related to the rear brakes.

Hi.

Quote:

The 1Z has a boost pressure control valve, which is not present in the AFN. Furthermore, the 1Z has an air hose leading to the control unit for pressure measurement. However, this is not the case with the AFN; the pressure is measured outside of the control unit.

I wouldn't have thought that the 1Z engine would have a different type of valve than the AFN engine.
While the AFN's turbocharger control uses vacuum (with 1Z being overpressure) and various valves, the electrical pin configuration remains the same.
That means replacing the engine computer, the turbocharger , and the solenoid valve, and the AFN should then run.

The pressure measurement, at least in my AFN , is done via a hose, similar to the 1Z , within the engine computer.
Perhaps there are differences due to the year of manufacture.

Hi everyone...

@Ulf:
Dirk mentioned the el/pneumatic converter for charge pressure control at AFN. The 1Z doesn't have that; instead, it has a pressure relief valve (which only opens and closes?) and is controlled differently.

Upgrading from a 1Z to an AFN (without a complete engine swap) isn't as reliable, because the AFN has also undergone mechanical modifications.
I also remember things like fuel injectors, but I'm not entirely sure what exactly they are or what they do anymore.

@AMB1980
I don't know of any G3 with 90 horsepower that has internally ventilated front disc brakes and no rear windows. It's possible the GT Special was different, but the 90 horsepower 1Z model I had came with 256x12 front discs and rear drums. Only the AFN (not a GTI) had 256x20 front discs and rear discs.

hello
Hey, thanks a lot for your tips, they are very informative.
But what I wanted to ask again is, do you also need to replace the control unit?
Actually, yes, because the ventilation control system is different on the AFN model, as far as I know. So, I would be surprised if it weren't.
Or what do you think?
You're welcome.

Hi.

Quote:

Dirk mentioned on the AFN forum the electro-pneumatic converter for charge pressure control. The 1Z doesn't have that; it has a pressure relief valve (which only opens and closes?) and is controlled differently?

As far as I understand the 1Z configuration, the boost pressure initially goes into the turbocharger housing, which opens the wastegate at approximately 0.6 bar.
The elpn. converter now allows a variable amount of normal pressure to be "mixed" into the hose leading to the can, which reduces the pressure inside the can, and consequently, the wastegate only opens at a higher boost pressure.

The wastegate is controlled by the engine control unit (ECU), which in turn monitors the boost pressure and ensures that the pressure does not rise too high.
However, this is only possible with a rapidly switching operation of the elpn converter. Otherwise, with (slow) opening and closing, the charging pressure would fluctuate up and down, causing the acceleration to oscillate.
So, it's the same basic principle of clocked control as with the AFN-VTG loader, but with a different loader operating mechanism.

@DieselDirk:

1. It's easier and only slightly more expensive to replace the entire axle than just the motor. Without the axle, you'll also need to buy new rotors, calipers, and brake pads.

Okay, I have a variant model, and it worked perfectly with the old exhaust. However, according to the speedometer, its top speed is 205 km/h, and it consumes around 4 liters on average (if you want it to).

3. Wiring harness. So, the TDI worked right away. It's just as Ulf described. The pin assignments are the same.

@AMB1980

The 90 PS models definitely do not have disc brakes. This applies to both the compact and the estate versions. Only the 110 PS compact model has disc brakes on the front and rear. The 110 PS estate model also has drum brakes on the rear.

So, if you're modifying a compact car, you might also need to replace the rear axle. At least for the 'variant' model, it's not cheap, and it's different from the version with drum brakes.

@map

I wouldn't start by replacing parts; it would become too expensive. The AFN engine, for example, also has different valves, two valve springs, different injectors, a turbocharger, crankshaft bearings, etc. I wouldn't bother with all that. Besides, you can still get a good price for your old engine. The upgrade I did, from a 90 hp engine with air conditioning (180,000 km) to an 110 hp engine with climate control (80,000 km), cost me about 1300 Deutschmarks in the end. That's still manageable.

The conversion from a 90 HP air conditioning system (180,000 km) to a 110 HP climate control system (80,000 km) ultimately cost me about 1300 DM. That's still manageable.

'1300 DM?? And with Climatronic even?? I would already be happy with just an air conditioning system in my car if it were included, but a motor, control unit, and transmission for that price? If you have another offer like this, please contact me...'

Best regards,

Dominique.

No, no.
I was planning on replacing the entire engine, including the engine control unit, exhaust, and rear axle, just as you all recommended.
Is that really all there is, because that certainly wouldn't be the whole world?
Okay, thank you again.
REFUSE.

@D. In short:

4500 DM für den AFN mit Vorderachse, Kabelbaum und Luftkasten incl. Climatronic.

I sold my old engine for 3500 DM. That price doesn't include small parts, the timing belt, coolant, etc., and the air conditioning refrigerant.

You should check out 'Zweite Hand' in Berlin sometime. They occasionally have some great deals.