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Engine Specific Info and Questions => IDI Engine => Topic started by: subsonic on June 26, 2008, 09:02:12 am

Title: Piston projection
Post by: subsonic on June 26, 2008, 09:02:12 am

Are the same numbers used for piston projection for both 1.6 MF and 1.9 AAZ?  Anyone know the part number for the 1-hole AAZ gasket?

Title: Piston projection
Post by: gigaz2 on June 26, 2008, 11:24:43 am

1Y and AAZ: (metal)

028 103 383 BH - 1 hole   - 1.53mm
028 103 383 BJ  - 2 holes  - 1.57mm
028 103 383 BK - 3 holes  - 1.61mm

have fun

Title: Piston projection
Post by: subsonic on June 26, 2008, 11:31:10 am

Thanks.  When I do the conversian for the one hole, it comes up to about .060 .  I may have remembered incorrectly, but I thought I was told my projection was only about .030.   So I am under?

Just found this:

   "Cylinder Head Gasket Selection On
                             1981-86 Volkswagen 1.6L (96.9 CID) Diesel Engines

The cylinder head gasket used in the 1981-86 Volkswagen 1.6L (96.9 CID) diesel engines is available in three thicknesses distinguished by notches on the side of the gasket.  The correct gasket is selected by measuring piston protrusion on all four cylinders and basing the selection on the highest piston height.

Protrusin should be measured as indicated in the illustration below by using Volkswagen tools VW382/7 and VW385/17 or equivalents.  It is important that your depth gauge/dial indicator set-up not rest directly on the piston itself to
prevent possible distorted readings.  Parallels placed on the deck surface next to each cylinder will provide a good base for measuring.

Use the following table for determining gasket usage:

Piston Height               Identification Notches

.0260-.0339                       1 (1.4mm thick)
(.66-.86mm)                        

.0343-.0665                       2  (1.5mm thick)
(.87-.90mm)                  

.0358-.0402                       3 (1.6mm thick)
(.91-1.02mm)

Additionally, be sure to install the cylinder head gasket with the side marked TOP or OBEN (on OE gaskets) facing up.  

                                                                                 The AERA Technical Committee"

It looks like there are some differences :?   This is a 1.6 block with a 1.9 head, so which one do I use?

Title: Piston projection
Post by: gigaz2 on June 26, 2008, 11:44:28 am

etka says:

JR or JP engine: (1.6 D/TD)

1 hole: 1.4mm
2holes: 1.53mm
3holes: 1.61mm

Title: Piston projection
Post by: subsonic on June 26, 2008, 11:50:50 am

So a 1 hole on a 1.6 is 1.4mm.  A 1 hole on a 1.9 is 1.53mm Which is closer to a 1.6 2-hole.  Yes?