[Vwdiesel] Head gasket choice?

[Andrew .Libby]

Have you accurately measured the piston protrusion at TDC for all 4
pistons?  In order to do so you must clean all carbon or foreign matter off
piston crown and engine deck. You then take the largest protrusion reading
and use the appropriate head gasket that matches that protrusion.  If you
are accurately measuring 0.5mm as the highest piston I would be a little
concerned as that is less protrusion than fits even the skinniest 1-notch
gasket which calls for 0.66-0.86mm (2 notch = 0.87-0.90 and 3 notch =
0.91-1.02).  The given spec readings make me wonder what you are supposed
to use if the protrusion is o.865mm or 0.905mm.  :-)

I have found that the wristpin is moved toward the crown typically 0.010"
per oversize in order to accommodate machining the engine block head gasket
surface.  Did you fit new pistons without having the headgasket surface
skimmed?

If your tallest piston protrusion is 0.5mm is there any chance the rods are
bent?

The 1-notch gasket seems to be particularly hard to come by.  It is part #
028103383BH (2-notch is suffic BJ and 3-notch is BK).  Looks like you have
the correct part although I'd probably disassemble the bottom end and have
a little skimmed off the block.  For future reference or anyone else who is
reading, if I am replacing the pistons, I measure the protrusion of the old
pistons, measure the wrist pin to crown height on both old and new pistons
and then do the math so that I can tell the machinist exactly how much to
skim off the head gasket surface without multiple trips to the machine shop
or multiple times assembling/disassembling the bottom end.  I have done so
on several engines and the piston protrusion has been exactly where I
wanted it each time.



On Thu, Apr 16, 2015 at 3:28 PM, Ralph Meyermann <ralphmeyermann at gmail.com>
wrote:

> Hi Volks! Currently assembling my AAZ and my pistons seem so come .5mm out
> of the hole. I bought a factory head gasket from my local vw dealership. It
> is a 028 103 383 BH DE. Is this thick enough? All I have is my 82 diesel
> westy Bentley and all my $$$ and then some has been spent on parts. Your
> help is greatly appreciated. Thanks!!!
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