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Engine Specific Info and Questions => IDI Engine => Topic started by: Smokey Eddy on September 08, 2008, 02:31:04 am
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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.
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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
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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.
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Yup there are some pics one the first page of the holes before/ after drilling.
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I did it on my mf block with no problem. Holes line up nicely with the aaz head. Can only help.
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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.
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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..
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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
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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..
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Crap.
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the 1.9 intake will need to be ground down a little bit to fit the turbo, well thats with a k24 anyway...
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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?
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You should measure piston protrusion and order the correct gasket accordingly.
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Ahhh Yes!
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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...
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Yeah, i have some hard starts a lot of the time and im thinking the comp. is rooockk bottom mostly to do with a messed up head but also too big a spacer inbetween the top & bottom
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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..
From the FAQ section:
Thanks go to fspGTD for retrieving this information:
1.6L
1980 Rabbit 1.6D:
* 3-notch (1.4mm): 068 103 383 FB
* 4-notch (1.5mm): 068 103 383 FC
* 5-notch (1.6mm): 068 103 383 FD
1981 Rabbit 1.6lD 11mm headbolt:
* 1-notch (1.4mm): 068 103 383 ES
* 2-notch (1.5mm) 068 103 838 ET
* 3-notch (1.6mm): 068 103 383 FA
81-84 Rabbit/Jetta 1.6 solid lifter 12mm headbolt:
* 1-notch (1.4mm): 068 103 838 FL
* 2-notch (1.53mm) 068 103 383 FM
* 3 notch (1.61mm): 058 103 383 FN
1986 Jetta 1.6 hydraulic:
* 1-hole (1.53mm): 068 103 383 EH
* 2-hole (1.57mm): 068 103 383 EJ
* 3-hole (1.61mm): 068 103 383 EK
The 11mm headbolt Vanagon CS engine code did get a unique head gasket:
1980-85 Vanagon 1.6 11mm headbolt (up to CS 000 338):
* 1-notch (1.4mm): 068 103 383 AT
* 2-notch (1.5mm): 068 103 383 ET
* 3-notch (1.6mm): 068 103 383 FA
Engine code JX:
* 1-hole (1.53mm): 068 103 383 FE
* 2-hole (1.57mm): 068 103 383 FF
* 3-hole (1.61mm): 068 103 383 FG
1.9L
1 hole (1.53mm) 028 103 383BH
2 hole (1.57mm) 028 103 383BJ
3 hole (1.61mm) 028 103 383BK
Looks like a 1 hole 1.6 hydro is the same as a 1-hole aaz.
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Ok so I'm using a solid lifter bottom end and a hydro head...
Confusing!
Ok not really. as to with the newer hydro engines the gaskets are the same as the AAZ's.
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Are the aaz gaskets hard to find? (ones that are well made, ie. not plastic/cork)
(this is turning out to be extremely insightful, thanks everyone)
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If you are in Canada you should be able to get them easier than we can in the states. We never got the aaz so no one carries parts except specialty shops. The aaz HG is considered a upgrade because it is a metal hg. Much better than the stock 1.6.
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just as a note the 1.9 tdi HG is metal also. I use it on my 1.6
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Ok, so as a bit of an overview or collaberation of questions i guess:
I think I have a hydro block (or at least i should? how can you tell...?)
I have to get an AAZ HG, i can't use a 1.9 TDI, right?
Drilling these "steam holes" do i have to get a machine shop to do that for me or can i skip doing that?
Can i transfer my 1.6 td hydro lifters (if they are ok) over to the aaz head?
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You do not have to add the steam holes, they are just a added efficiency. A machine shop does not have to do it. You can lay on the aaz hg and mark the hole posistions with a marker, remove the hg, give each mark a little wack with a pointy abject to make a small dimple, use a hand drill, straight up and down, drill away. The drill dia can be a bit smaller than the hole size. Just be careful with chip cleanup, tape off etc.
What does the head you pulled off look like? Does it have 2 bumps on the front or one? If it is off you can look at you lifters as well. Do they have a small circle on top with a shim in it? that would be a mech head, smooth tops would be a hydro head.
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do the mech blocks also have the bumps? IE do they follow the head?
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i seem to recall actually reading that the AAZ gasket thickness is more than a 1.6 but i guess i could be wrong...
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it depends, seems like Hydraulic block HG have the same thickness.
mechanical are slimmer(for the same number of holes)
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What does the head you pulled off look like? Does it have 2 bumps on the front or one? If it is off you can look at you lifters as well. Do they have a small circle on top with a shim in it? that would be a mech head, smooth tops would be a hydro head.
I know I have a hydro head. I'm wondering about the block. I have no idea what has been done to this car. Obviously lots (of bad things), poor thing.
Again, can you transfer hydro lifters to the AAZ?
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do the mech blocks also have the bumps? IE do they follow the head?
No, the second smaller oil drain to the right isn't there it actually overlaps a coolant passage, thus all the threads on how to fit a AAZ HG to a 1.6. Same thing, the ports line up differently.
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Again, can you transfer hydro lifters to the AAZ?
Do you have the lifters?
Do you have the AAZ head?
Measure..
I think they are the same, hopefully someone with a bit more knowledge will chime in.
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034109309AD
yap, AAZ and the hydro 1.6 share the same reference, so yes, you can
EDIT: knowlegde... you mean ETKA :D
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EDIT: knowlegde... you mean ETKA :D
Exactly what I meant.
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Ooooooooooo
It's nice having an ETKA of our own the forum :P
but seriously, thank you very much
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It's an old topic, but here goes anyway:
Since I'm putting an AAZ head on my 1.6 TD, are there any other valve covers that fit instead of the original AAZ one?
I even bought a G60 valve cover but after switching to 1.9 head that's no longer an option and I sold it on.
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It's an old topic, but here goes anyway:
Since I'm putting an AAZ head on my 1.6 TD, are there any other valve covers that fit instead of the original AAZ one?
I even bought a G60 valve cover but after switching to 1.9 head that's no longer an option and I sold it on.
you could of used that G60 cover you just needed to drill and tap the 1.9 head for it!
thats your only option unless you have something CNC machined custom?
Duane
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im drilling my aaz head (once i get it) to fit the stock 1.6 CC and modify it a bit to use the top mounts the aaz head uses too