aaz head on 1.6

[Smokey Eddy]

with a 1.9aaz head onto a 1.6 with a garett t3 are there any or many mods to the manifolds or anything for that matter that I should allot time for in my build?

Scratch the DP and exhaust. I'm making my own 3 inch.

[subsonic]

As long as you have the 1.9 intake, you should be all set.  There are some things you could do if you want.  Assuming that your 1.6 is  hydro, you can lay on the aaz hg, mark and drill the steam holes that the 1.9 block has but the 1.6 does not.  They will match up to the 1.9 head.
 
You could gasket match the intake and exhaust manifolds, as well as the ports on the head.  Other than that, general clean up removing casting lips etc.
http://www.vwdiesel.net/phpBB/viewtopic.php?t=4308&highlight=steam+holes

[zukgod1]

As long as you have the 1.9 intake, you should be all set.  There are some things you could do if you want.  Assuming that your 1.6 is  hydro, you can lay on the aaz hg, mark and drill the steam holes that the 1.9 block has but the 1.6 does not.  They will match up to the 1.9 head.
 
You could gasket match the intake and exhaust manifolds, as well as the ports on the head.  Other than that, general clean up removing casting lips etc.
http://www.vwdiesel.net/phpBB/viewtopic.php?t=4308&highlight=steam+holes

To bad all those pics are gone..
I'll look but I think I took pics of this in my build thread.

[zukgod1]

Yup there are some pics one the first page of the holes before/ after drilling.

[subsonic]

I did it on my mf block with no problem.  Holes line up nicely with the aaz head.  Can only help.

[jtanguay]

I did it on my mf block with no problem.  Holes line up nicely with the aaz head.  Can only help.

actually don't forget that the AAZ gasket thickness is indeed more, and will result in a slightly noisier/rougher cold start... you can compare the thicknesses in the bentley.  but for high boost, and reliability, it is definitely worth it! i'll take a little rough start in the winter for a reduced chance that it will blow a hg.

[zukgod1]

I did it on my mf block with no problem.  Holes line up nicely with the aaz head.  Can only help.

actually don't forget that the AAZ gasket thickness is indeed more, and will result in a slightly noisier/rougher cold start... you can compare the thicknesses in the bentley.  but for high boost, and reliability, it is definitely worth it! i'll take a little rough start in the winter for a reduced chance that it will blow a hg.

I was wondering about that.

I wasn't able to find the specs on the AAZ to compair though.
I went with a 1 notcher and was on the edge of the specs but thought I remembered reading somewhere about the AAZ gasket being a tad thicker so I went for it.
Worked out ok so far..

[Smokey Eddy]

I have a 3 notch 1.9 TDI metal HG in my 1.6 and it works fine. I was just going to use that one.

Is that indeed the same HG as the AAZ?
this metal HG one i got has all the exact holes as the 1.6 ... no extra ones... doesnt block any of them

[zukgod1]

I have a 3 notch 1.9 TDI metal HG in my 1.6 and it works fine. I was just going to use that one.

Is that indeed the same HG as the AAZ?
this metal HG one i got has all the exact holes as the 1.6 ... no extra ones... doesnt block any of them

The TDI one isnt the same as the AAZ gasket..

[Smokey Eddy]

Crap.

[RabbitJockey]

the 1.9 intake will need to be ground down a little bit to fit the turbo, well thats with a k24 anyway...

[Smokey Eddy]

Anyone know for a t3?
Also, on a side note....

I've always used three notch head gaskets. Could I, Should I, use a 2 or 1 notch when i get a new aaz head?

[zukgod1]

You should measure piston protrusion and order the correct gasket accordingly.

[Smokey Eddy]

Ahhh Yes!

[jtanguay]

I have a 3 notch 1.9 TDI metal HG in my 1.6 and it works fine. I was just going to use that one.

Is that indeed the same HG as the AAZ?
this metal HG one i got has all the exact holes as the 1.6 ... no extra ones... doesnt block any of them

The TDI one isnt the same as the AAZ gasket..

depends if you're talking 1Z/AHU or ALH... i believe the 1Z/AHU gasket will fit (just ask Jimfoo when he used it on his 1.9 AAZ block with the TDI head).  OTOH, the ALH gasket will CLEARLY not fit, and anyone with half a brain should be able to determine that upon installation  :lol:

and yes.. measure your piston protrusion to determine the gasket you need.  but at the same time if you're borderline 3 notch on your 1.6, then you *might* be able to get away with a 2 notch...  apparently more is affected than just the CR when you go too high on the thickness...