1Z Refurbishment

Hello fellow DIY enthusiasts!

Unfortunately, I have to bring up a topic that has been discussed many times before. I want to convert my 1Z to an AFN engine, and I have some questions about the process. Normally, I would just start working on it, but experience has shown that my modifications and repairs tend to take much longer that way, and I want to avoid that this time by carefully planning my project with your help.
The search function has answered some of my questions, but not all of them. I'm aware that most of you would consider a rebuild to be impractical and would recommend replacing the engine. Since I'm planning a complete overhaul anyway (the 1Z and AFN engines have the same block), the base engine type doesn't matter in my case.

Regarding the renovation:
In the first phase, I want to install a Turbo (VNT 17 from a 130 PD engine), a fuel pump (ALH automatic with 11mm pistons), and an engine control unit (ECU) from an AFN (with original software). Before you all jump in and say, 'Nozzles need to be replaced too,' I already have 216s installed.

In the second phase, which is currently only planned for the summer, the engine block, cylinder head, clutch/flywheel, and, most importantly, the tuning of the engine control unit on a test bench will be addressed.

But for now, I would like to focus on Phase 1. Okay, here are my questions:

'Can I keep the intake manifold from the 1Z engine if I use an exhaust manifold from the AFN engine? Specifically, do the flanges align correctly on the cylinder head side? And what about the EGR valve? I want to block it off.'

2.) Regarding the impeller on the ALH pump: Can I install the ALH pump directly, or do I need to obtain and install an impeller from an AFN engine?

3.) Regarding the turbo control: After the vacuum pump, the AFN also has a vacuum reservoir to compensate for pressure fluctuations (providing a more consistent vacuum for the variable geometry turbocharger) - Is a modification necessary?

4.) Are the oil connections the same on the 1Z ATL and the VNT17?

5.) Can I use VAG-Com to adapt the new control unit to my car, or does my car even have a WFS (Whole Vehicle System)?

I've already acquired the following parts - what else do I need for the conversion?

Turbo (VNT17)
Hose for compressor outlet (from ARL).
Exhaust manifold + gaskets + screws.
Exhaust system AFN.
Fuel injection pump ALH.
Engine control unit (ECU) AFN (Passat 96, AFN).

Okay, I think I have everything for now. I'm looking forward to your responses.

greetings
Wolfgang.



*Passat Variant CL, MBK: 1Z, Year of manufacture: 1994, faulty AGR (Exhaust Gas Recirculation), reinforced clutch, 216 injectors, chip tuning, 10-cent spark plug, water/methanol injection, 0-60 mph time: < 5.5 seconds with a weight of 1400 kg.*

Hello Wolfgang.

It is possible to convert from a 1Z engine to an AFN engine; I also converted the engine in my previous car.

You can use the intake manifold without any problems if you remove the EGR valve.
you no longer want to use (simply close it with two metal plates).
There are no problems with the exhaust manifold from AFN!!

I'm not sure about the impeller and ALH pump.

A vacuum reservoir and check valve are required; otherwise, it will not function.
the control of the VTG.

4. You'll need to bend the oil feed line slightly to make it fit, but otherwise, the fittings are compatible.
You need an original oil return line; the one from a 1Z model won't fit.

5. You can easily have the AFN engine control unit adjusted using VAG diagnostic equipment.
The prerequisite is that you have an immobilizer; if not, you would need to have one installed.


Okay, I hope this helps you.
Good luck with the renovation.

Sincerely,

Patrick.

Are you watching that?

http://www.meckisfaq.de/antworten/motor/diesel/1z_2_afn.htm

That should answer all the questions and be part of the...
Illusions shatter.

Unfortunately, it's not that easy, but as they say, anything is possible if you want it badly enough.

@ Patrick,

Thank you for your answers - you saved me a lot of time and trouble!

@SoupOfTheDay

I was already familiar with that link, and besides, it doesn't answer any of my questions. 'Thank you anyway.'


Okay, so it seems almost everything is clarified – I hope someone can still answer my question about the hub.

greetings
Wolfgang.

Hello everyone!

I just wanted to share my experiences regarding the renovation:

We (two people) took about a day to complete the mechanical conversion, with the disassembly process, especially loosening the stuck screws and nuts, taking the most time. Specifically, the screws connecting the catalytic converter to the exhaust pipe and the turbo exhaust side to the exhaust pipe were so severely corroded that we had to use heavy-duty equipment in some cases (e.g., freezing spray, gas torch, mini-angle grinder).
Quite the opposite, actually. The new charger/manifold fits much more easily and better. The access from above is now also much easier than with the old loader.

'Stolpersteine':
1) seized screws
2) The 1Z model is missing the bracket that supports the catalytic converter. Instead, the turbocharger is connected to a block via a bracket on its underside. Solution: either install the bracket from the AFN model or create a custom-made solution!
3) EGR valve blockage: A 1mm thick steel plate was screwed onto it, but it couldn't withstand the pressure and started to vibrate. Solution: The section of the EGR return pipe was cut off and, along with a small piece of material, it was attached (clipped) in place, and the unpleasant noise disappeared.

Okay, so those were the mechanical problems, but now I have a much bigger issue, and it's with the electrical system.
I tried to use VAG-Com to adapt my new control unit to my immobilizer, but I couldn't log in to channel 25 (immobilizer). So, I searched the forum and found out that Passat models produced from 10/1994 onwards were equipped with immobilizers, but my car was manufactured in 07/1994. So, I did a little research and found out that I have two options:
1) Retrofitting an anti-theft immobilizer system (key, reading coil, circuit board adapter, wiring, etc.)
2) Program the engine control unit (ECU) so that the immobilizer is deactivated.

To be honest, I'd like to avoid the first option, and for the second option, I either lack the necessary expertise or the funds. The local tuner would do that, but they require a complete chip tuning package for it.

Okay, here's the translation:

'Now my question: Can anyone of you tell me how to disable the immobilizer in the ECU?'

Sure, here's the translation:

'Thx' translates to 'Thanks' in English.
Wolfgang.

Hello NVE,

I doubt anyone will readily provide you with that kind of information, especially not in a forum. This could then allow all car thieves to go around freely, and the WFS (presumably a security system) would become quite useless.

The WFS (Window Field Sensor) in Audi 80 and Golf3 models is located externally, not within the instrument cluster, so the retrofit process shouldn't be too complicated. I can't imagine these things are expensive. They're available in every Golf3 from 1994 onwards, and plenty of them are being salvaged. And the WFS probably isn't one of the most sought-after parts for salvage. Maybe you'll even find the matching wiring harness and key (for transponder conversion) along with it. Just take a look at eBay (e.g., http://cgi.ebay.de/ws/eBayISAPI.dll?ViewItem&item=2458524390)) or ask the sellers who are offering their Golf 3 in parts.

The wiring probably isn't too complicated either.

I'm sorry I don't have better news for you.

Regards,
Private.

Regarding the flexible pipe for the 1Z model:

This is a complete design flaw and a major vulnerability.

Therefore, the AHU also received the AFN construction.

Since the AHU is a 1Z engine, the AHU catalytic converter (everything from the Turbo model onwards) should fit the 1Z.

The crossbar, which costs 22 EUR, naturally needs to be retrofitted .

Hello,

Latest update:
According to information I received from Volkswagen, retrofitting the WFS (Wireless Full System) is quite complex. Since I don't have any shift paddles or much information about the WFS, it's not something I'm interested in doing.
The second option, having it unlocked by the tuner, is possible, but it would cost 500 euros at a tuner near a VW dealership. Further inquiries were met with responses stating 'it involves too much risk for us.'

However, there is still hope: According to information from VW, there are AFN engine control units (ECUs) that do not have an immobilizer. Unfortunately, they were unable to tell me which part numbers these are. Therefore, my request: Does anyone happen to know the STG number for an AFN engine control unit (ECU) without WFS?

Thank you all in advance for your answers!

greetings
Wolfgang.