1.9TD "AAZ" Conversion

[Baxter]

When I went to the 25 years of Syncro event at Mammut Park I saw a couple of Iltis there running 1.9TD engines.
I have a couple of questions as I have just started this conversion myself.

1. What do you do for oil filters? I know the Canadian Iltis uses a remote filter, but that was on a 1.6TD not a 1.9TD, I cannot use the 1.6TD filer head as it doesn't fit the 1.9TD engine.
I propose to use a filter head (bracket) from a 1.9TD "ABL" engine from a T4, the n use a take off plate to a remote filter then onto a thermostat to a external oil cooler in front of the radiator. can anyone see any problems with this system?

2. My next problem is the clutch, mine is toast! so I need to buy something, is there anything stronger than will fit easily? taking into account that I have put a 1.9TD in and intend to modify it.

Kind regards.

Simon.

[MacSchreck]

Hello Simon,

specific to the oil filter element, the filter should be the same for the 1,6td and the 1,9td engine (e.g. MANN FILTER W 940/25). I use it inside my engine and to relate to the 1,9td AAZ,AEY,1Y,JP,ME...... engines it should be the exactly the same element.
The 1,6td has the remote filter made by FRAN/Canada.

I´m not a specialist for clutches, but i found out this webside:

http://www.verstaerkte-kupplung.de/catalog/?gclid=CL-y5snN36MCFcGOzAodFCC8xg

maybe it is interesting for you.

Greetings

Markus

[Baxter]

Hi.
It wasn't the filter, but the filter holder I was struggling with.
The Iltis item is angled backwards away from the engine mounting and clutch cable holder, the AAZ item will interfere with this.
I don't think I can use the iltis holder on the AAZ as it will touch the engine mounting.

[Snoop]

Hi Simon,

I think a remote filter system, as you requested, should be no problem.
Also it is the only way to install an additional oil-cooler.

Original clutches for the Iltis are only available from "LUK".
All other offered stuff is not really stronger - maybe cheaper.

[www.iltisteile.com]

i have stronger clutchs available, but rather expensive
this is motorsport equipment

just email me

[marc_em-pr183]

Hi Simon,

was not in this forum for some time, so sorry for late answers...

You can use the filter holder from Audi 100 1.6D or TD, also from Audi A4 1.9 TD or DTi. The are kind of 45° shape and have 3 channels instead of 2 channels. The only issue is that they are shorter than the VW ones. So you will need to make an adapter that is maybe 1 inch in thickness that you put between the motor block and the filter holder. We've done it this way for AAZ and 1Z conversions.

Regards,
Marc

[Baxter]

I bought the parts from Mocal in the end.
I have not yet updated www.iltis.co.uk as I have been busy with work (T3 TDI conversion) plus the apprentice has been on holiday.
I used a filter head from a Audi that is swept backwards, I have then used a take off plate with pipes to a remote filter head.




I then have a thermostatic sandiwch plate which is going to a 13 row oil cooler behind the grille.


My apprentice cannot really help me with the TDI conversion so for the next few days he is on Iltis duty!

The Iltis clutch was not available to buy in the UK, I used the Audi item. Dimensionally identical, the springs in the clutch disc were however much larger than the Iltis item. The clutch that came out was 100% original and still had "Iltis" painted onto it.
I have kept the pressure plate incase that is stronger than the Audi item but as I say they looked identical. The Audi item was fitted to engines up to 2.1l in capacity, I'm confident that it is up to the job.

[marc_em-pr183]

[quote Baxter]I bought the parts from Mocal in the end.
--8<---
[/quote]
Ok, that works fine, too and might be even better for the AAZ since it gets hotter than the TDI. Not as hot as the 1.6TD but still hot.

[quote Baxter]
The Iltis clutch was not available to buy in the UK, I used the Audi item. Dimensionally identical, the springs in the clutch disc were however much larger than the Iltis item. The clutch that came out was 100% original and still had "Iltis" painted onto it.
I have kept the pressure plate incase that is stronger than the Audi item but as I say they looked identical. The Audi item was fitted to engines up to 2.1l in capacity, I'm confident that it is up to the job.
[/quote]

I do not really get it what you took from what but talking about clutches: we just built an AFN into an Iltis and we have issues with the cluth. It kind of vibrates under high momentum to transfer. It is not an original Iltis clutch but Passst 32b 1.6D from Sachs. However, it is clear that a clutch that is designed for the original 1.6TD with 135nm @2800upm will be at the limit for a 1.9TDI with 235nm @ 2000upm. However, with the 1Z we did not have this issue so far. What kind of clutch set do you use for the T3 TDI and is this an AFN or 1Z motor?

Regards,
Marc

[Baxter]

We used the original Golf clutch in the T3, shaved 4mm from the diameter of the flywheel to stop it fouling the starter motor nose.
we have fitted a 1Z motor.
We have the plate between the engine and gearbox made from sheet stainless steel so the lump on the 1Z flywheel does not foul it.
If you fitted a 1Z to a Iltis I should imagine you also have to remove the casting by the thermostat housing and the 2 lumps from the engine block so that the starter motor fits?
I did think about a TDI for the Iltis but it's the gearing that is the problem, you would not be able to drive at motorway speeds without modifying the gearbox? Unless you can tell me different?

[chrislb]

[quote Baxter]
I did think about a TDI for the Iltis but it's the gearing that is the problem, you would not be able to drive at motorway speeds without modifying the gearbox? Unless you can tell me different?[/quote]

Good morning, Simon,

you're right, a diesel engine without a modified gearbox is not really suitable for road use and an absolute nightmare on motorways.
There are some specialists who have modified the Iltis gearbox, using gear wheels from other Audi models, and also the Audi-based Porsche 924. The fourth gear should be considerably longer, the third slightly longer.
It was stupid that VW equipped the last series of the Iltis with diesel engines without changing the gear ratios.

By the way: all VW diesel engines with cast iron blocks and alloy cylinder heads are grateful for careful warming up!

[Baxter]

I'm interested in the taller 4th gear, do you have any more details?
The AAZ revs reasonably high for a Diesel hence why I chose it, as far as I know it is the highest revving Diesel engine that VW produced.
It is also not that hard to make it rev more, simple governor modifications release more power and let the engine rev.
I hate Petrol engines, they smell too much.
I know about the cast block, I keep having to chop bits off to get it in the engine bay properly!

I have used a 80°c thermostat as the AAZ does run warmer than a 1.6TD, plus I have used the original radiator (rebuilt) so I thought that would be a useful addition along with the oil cooler.
I also intend to fit a coolant temperature gauge as well as boost and EGT.

[www.iltisteile.com]

i hate diesel engines, they sound weird and their reek is an anathema to since i stood many times behind my tank to warm me up in winter
but hey, many poeple are frozen, none of them perished of smell

i do tranny conversions, it's not too hard, but you need proper equipment (you sure have)
the pinions i have in stock (+11%)
for warranty reasons i modify only new gear boxes, so bearings and sealings are new and easy to disassemble

i advice you to take the bombardier radiator, it holds almost 2l more liquid
also the additional (diesel) oilcooler with fan is a good add-on (but hard to get, almost no diesels are stripped for pieces)

[Stinkmarder]

[quote www.iltisteile.com]
i do tranny conversions[/quote]

This sounds a bit... strange.

But I'm sure your mean transmissions, not....




Oh and (to keep this on topic) - I agree on the diesel issue. Diesel stink.
There are some good petrol engines you could use in the Iltis. I prefer the PF engine.

Regards
Johannes

[Baxter]

I don't have blood, I have Diesel.

[chrislb]

[quote Baxter]... The AAZ revs reasonably high for a Diesel hence why I chose it, as far as I know it is the highest revving Diesel engine that VW produced.
It is also not that hard to make it rev more, simple governor modifications release more power and let the engine rev.
...
I have used a 80°c thermostat as the AAZ does run warmer than a 1.6TD, plus I have used the original radiator (rebuilt) so I thought that would be a useful addition along with the oil cooler.
I also intend to fit a coolant temperature gauge as well as boost and EGT.[/quote]

I get the feeling that there's quite a lot of VW diesel expertise on the other side of the channel. From T3's, Synchro's etc. and now also Iltis.
Wouldn't it be great to have a complete conversion story of the AAZ Iltis? Simon, many members of the community would be grateful!
It was always my opinion that a vehicle like the Iltis should be equipped with a diesel engine (all my other cars are diesel burners, with the exception of one rotary).

One question:
Am I right assuming that the governor is the rev limiter? I'm not sure.