I thought using a German forum, with German cars and German inhabitants I would be "teaching grandma to suck eggs" (that's an Enlish term for telling you something you already know!)
I have pictured the improtant bits on
www.iltis.co.uk but i didn't document much of it as I didn't think anything that I was doing was in any way special, or groundbreaking.
It's just been VW lego, taking the right combination of VW parts and arranging them in the right order to get it to work.
The 1C engine fitted to the Iltis, the VW 1.6TD is very similar of that fitted to Golf2 GTD and Passat3 amongst others, I have used the turbo set up from that.
I have used the AAZ 1.9TD engine from a Golf 3.
I have used the AAZ injection system.
I have used some Audi or other oil filter head.
If I were to do it again I would probably look to use the oil filter head from a Audi 80 with the AAZ as it has the right shaped oil filter head with the oil cooler set up, but finding those in the UK is very difficult.
AAZ engines in the UK command a high price as they are so popular to replace T3 1.6TD "JX" engines that have expired, seems stupid to take a blown engine out and not replace it with something better for the same amount of work.
As for the governor, yes, the speed limiter as such, how is your English?
www.vwdiesel.net has a great wealth of knowlege, plenty of FAQ's about getting the best from your injection pump.
There is a proceedure, the "governer mod" which entails increasing the pre load on the intermediate spring in the governor by use of small washers (3mm from memory) to in effect riase the fuel "map" up the rev range, this will let the engine rev more.
There are also boost and fuelling modifications which are not difficult which really lets these engines fly.
AAZ engines run warm, much warmer than a 1.6TD so they really need oil coolers, an intercooler would be good on an Iltis but it's finding a suitable home for one where it will get good air flow and not get clogged with dirt, for the moment I will not be fitting one.
A EGT gauge (Exhaust Gas Temperature gauge, or Pyrometer if you prefer) is invaluable when messing about with Diesels as it lets you see how mad you have gone! It is a safety blanket!
Add too much fuel and you will raise EGT and you could melt a piston or damage the turbo.
More boost = cooler EGT
More fuel = hotter EGT
Tuning Diesels is all about striking the right balance between power, smoke, economy and EGT.
