Anyone with an AAZ Head Gasket Chart handy? - IDI Engine - VWDiesel.net The IDI, TDI, and mTDI source.

• Anyone with an AAZ Head Gasket Chart handy? by Jetmugg on 24 May, 2013 10:16
• I just assembled the bottom end of my 1.5L engine last night.  I have the Bentley manual for the 1.5/1.6 engines, showing the correct head gasket chart for a stock 1.5/1.6.
  
  
  
  
  I will be bolting on an AAZ cylinder head.  I don't want to purchase the entire Bentley manual for an AAZ equipped vehicle just to get a look at the head gasket chart.
  
  I think there's a high likelihood that the overall HG thickness charts will be very similar between the fiber gaskets of the 1.5/1.6 and the MLS gaskets for the AAZ.  However, I would feel much better if I could lay my eyes on the actual chart for an AAZ (MLS) head gasket selection.
  
  Any help would be appreciated, most especially if someone could post the data from the actual chart showing piston protrusion and gasket selection.  I have done several searches, but haven't found data from the actual AAZ chart.
  
  Thanks,
  
  Steve.
• #1 by burn_your_money on 24 May, 2013 10:21
• It's in the FAQ somewhere
  http://www.vwdiesel.net/forum/index.php?topic=6741.0
• #2 by Jetmugg on 24 May, 2013 11:25
• Thanks for the link. 
  
  I've seen the chart you posted in multiple locations, but not the "decision making" chart for an AAZ that determines which gasket to use based on the amount of piston protrusion.  I'm measuring piston protrusion in the range of 0.039" to 0.043" when checking all 4 pistons.  I'm pretty confident that I'm going to need the 3-notch MLS gasket, but would feel a lot better about the decision if I could feast my eyes on the actual selection chart.
  
  Thanks,
  Steve.
• #3 by libbydiesel on 24 May, 2013 12:05
• 0.043" is more protrusion than the spec for the three notch (thickest).  The greatest allowable protrusion according to spec is 1.02mm (0.040").  I would swap pistons/rods from the greatest to the least and see if you can get them all under 0.040".  If not, I would have the rod big-ends redone and moved toward the small end the appropriate amount. 
• #4 by Jetmugg on 24 May, 2013 13:46
• Thanks for the tip, Libby.  I am actually tempted to take a light cut on the top surfaces of the pistons.
  
  Libby - I'm hoping you might know:  Is the head gasket thickness expressed in terms of the compressed thickness, or uncompressed?
  
  (i.e. is the 1.6mm thickness for a 3-notch gasket the in-service thickness, or before being compressed?)
  
  Thanks again,
  
  Steve.
• #5 by burn_your_money on 24 May, 2013 14:03
• Quote from: Jetmugg on 24 May, 2013 11:25

  Thanks for the link. 
  
  I've seen the chart you posted in multiple locations, but not the "decision making" chart for an AAZ that determines which gasket to use based on the amount of piston protrusion. 
  

  
  Oh right. Myke_w did post it in the very last post in the thread, but he doesn't specify AAZ or 1.6 gaskets. I'll try and remember to take some pictures next time I have my Bentley out to update that thread.
• #6 by RockOcean on 15 May, 2017 22:43
• I just found this in a thread, not 100% sure thats what the Bentley says tho. Can anyone confirm?
  
  1 notch - 1.53mm thick to suit piston protrusion of .66mm to .86mm
  2 notch - 1.57mm thick to suit piston protrusion of .87mm to .92mm
  3 notch - 1.61mm thick to suit piston protrusion of .93mm to 1.02mm
  
• #7 by RockOcean on 18 May, 2017 00:47
• The Bentley says:
  
  1 notch - 1.53mm thick to suit piston protrusion of .66mm to .86mm
  2 notch - 1.57mm thick to suit piston protrusion of .87mm to .90mm
  3 notch - 1.61mm thick to suit piston protrusion of .91mm to 1.02mm
• #8 by RabbitJockey on 18 May, 2017 08:48
• back from the dead haha
• #9 by RockOcean on 14 Aug, 2023 11:01
• Bringing this waaaay back from the dead.
  
  Just curious to know why the 2 notch gasket only has a variance of .03mm the 1 notch has a .20mm, and the 3 notch a .11mm variance?