Tuning: 1Z Engine Conversions & Upgrades

'As a young person, I'm looking for someone who might be able to give me some tips on the mechanical modifications I'm planning for my 1Z engine (originally 90 hp). I want to replace the charge air pipes with aluminum ones for aesthetic reasons (I've seen various modifications with stainless steel, but it's... too expensive!). Also, I've heard that the standard charge air pipes are prone to cracking above 1 bar of boost pressure. Can anyone confirm this? I once drove a 1Z engine that had been modified and was running (according to the boost gauge) 1.3 to 1.5 bar of boost, and the dyno showed that engine produced 164 hp. I don't necessarily want to go that far, but I'm interested in that kind of performance.'
Does anyone know the optimal diameters (50, 55, or 60)?
Has anyone ever done a conversion like this? I'm looking for people to share their experiences. Also, could someone provide a link or a bibliography as a source for information about the racing version of the Golf 3 TDI? I used to have a magazine with the exact technical specifications (called 'KRAFTHAND'), but I threw it away... *sigh*...
Where can I best obtain the rubber connectors used between the metal pressure pipes? Are they available from truck manufacturers? Or somewhere else?
Does performing an external fuel pre-heating or removing the crankcase ventilation system from the intake manifold to achieve cooler fuel intake have any benefits?
And finally, a last question... Is it correct that a larger volume of compressed intake air located in front of the intake valves (like in an SDI intake manifold) improves the engine's response? Thank you in advance to everyone who has read this far, and a huge thank you to anyone who has any tips for me... Matze ([email protected])

I have 2 PDFs on that topic; if you are interested, please send me a private message .

Hi,
'I also own a 1Z Passat with a boost pressure of 1.1 bar, running the pump at its maximum capacity as far as the chip allows. I replaced the boost pressure pipes with stainless steel ones that I made myself. Additionally, I modified the air intake to the intercooler, allowing approximately 100% more air to flow in. The difference before and after the modification is significantly noticeable. According to the dyno, the engine produces about 125 hp and 307 Nm of torque (possibly a bit more now).'

Hi Tim,

Can you describe it in more detail, or even take some pictures of it?
How did you modify the LLK?

Greetings,
Thomas.

hello,
'How did he manage to get almost 165 horsepower out of a 1Z engine? He must have replaced the injectors and fuel pump, right? Otherwise, it's not possible with that engine. The turbocharger also only produces a maximum of 1.5-1.6 bar, maybe 1.7 bar at most, which is what mine achieves (I've tested it). If the boost pressure is actually set to 1.3-1.5 bar, the needle always moves to the extreme right when you accelerate. What's his torque output?'

Hi,

http://www.rothe-motorsport.de/html/bildgalerie/go3_007/seite1.htm

They changed more than just the pump, turbocharger, and injectors.

Greetings,
Thomas.