different head gaskets? 1 2 or 3 hole?...

Joined
Jul 26, 2005
TDI
Jetta, 2001, black
Long story as to why, and NNNOOOO it was not the timing belt....:p turbo died and sucked motor dry of oil:eek: , but I am rebuilding the engine on my 2001.

I see there are 3 different head gaskets. 1, 2, or 3 hole markings.

Near as I can see they all have the same hole sizes and patterns so what is the difference?

Mine had a 2 hole and the replacement I picked has 3 holes.

Will this work?

If not, why not?

I want to know.

thanks!
 

dataiv

Veteran Member
Joined
Feb 12, 2005
Location
Ottawa, ON
TDI
2015 Golf Wagon TDI 6MT
The holes are there to tell you what thickness the head gasket was. If your existing head gasket was a 2 hole, you need to use a 2 hole. It says this in the Bentley manual - you are not supposed to interchange them.
 

compu_85

Gadget Guy
Joined
Sep 29, 2003
Location
La Conner, WA
TDI
... None :S
As I understand it, the more holes the thicker the gasket is. So by installing a 3 hole in your engine that came with a 2 hole, you will be lowering the compression ratio.

-Jason
 

tditom

Top Post Dawg
Joined
Sep 5, 2001
Location
Jackson, MI
TDI
formerly: 2001 Golf GL, '97 Passat (RIP) '98 NB, '05 B5 sedan
and if you replace a 2 hole with a 1 hole you could incur valve/piston interference!
 

redmondjp

Veteran Member
Joined
Jul 1, 2004
Location
Redmond, WA
TDI
'96 Passat Sedan
Common phrase: Up the creek w/o a paddle.

TDIclub version: Apart the engine w/o a Bentley (manual).

There are soo many ways you can screw up things when you reassemble your engine, let me count the ways . . .

Seriously, before touching your engine again, do yourself a huge favor and order a Bentley manual for your car--it costs about the same as it would to take your car to the dealer to diagnose a check-engine light.

You need to check the piston protrusion from the block in order to determine which head gasket to use--if you are reinstalling the exact same head and it wasn't surfaced, then you want to use the same number of holes as on the gasket that was on there originally.

Also, there are several torque-to-yield bolts that MUST be replaced or you risk having your engine fall part-way out while you drive down the road (no joke :( ). Not to mention the critical nature of properly setting your cam and injection pump timing (or you risk trashing your head). All covered in the Bentley manual.
 

tditom

Top Post Dawg
Joined
Sep 5, 2001
Location
Jackson, MI
TDI
formerly: 2001 Golf GL, '97 Passat (RIP) '98 NB, '05 B5 sedan
the Bentley for my ecodiesel had steps for measuring piston protrusion and selecting the correct gasket from a chart. The Bentley for my Passat does not have any mention of measuring and only says to use the same type on replacement. I've never looked at my A4 Bentley.

Both manuals mandate the replacement of head bolts too.
 
Joined
Jul 26, 2005
TDI
Jetta, 2001, black
ok, ok. the id may say newb, but I most certainly am not!

you mean I have to open and read it? LOL!

yes I have a manual... and new head bolts.

I figured it was something like that but I didnt want to take it out of the wrapper to measure it. back to store we go...
I figured it was easier to check with you guys!

thanks!
 
Joined
Jul 26, 2005
TDI
Jetta, 2001, black
say - since I dont have it here. does anyone know the numbers for when to move to a 3 hole from 2? I had the head cleaned up but cant reach the machinist to get the amount he took off right now. depending on the amount he removed I might be good with the 3 hole.
 
Joined
Jul 26, 2005
TDI
Jetta, 2001, black
thanks Birdman!

if I am reading that right - if the shop cut 30 thousands off the head I should stay with the 3 hole. If not I need to go back to the store..

I knew there was a reason to come here today!

thanks guys!
 
Last edited:

Keith_J

Veteran Member
Joined
Apr 12, 2007
Location
West
TDI
2000 Jetta MT
2001jettaTDI19 said:
thanks Birdman!

if I am reading that right - if the shop cut 30 thousands off the head I should stay with the 3 hole. If not I need to go back to the store..

I knew there was a reason to come here today!

thanks guys!
Watch out. 30 thousandths of an inch is 5 times the difference between the single and three hole gasket thickness. The valves in a new head are about 20 thousandths off the face, if the head is milled, that would make it over 50 thousandths which will be a problem even with a 3 hole. You will have an interference of 26 thousandths on all valves, all the time. That is the thickness of over eight sheets of regular paper...something has to give and that will be the tappets.

Now, if the machine shop also installed the seats a bit deeper so valve protrusion from the head remains at 20 thousandths, all is fine.

Measure the valve protrusion. Note, the Bentley does not permit milling the head. Maximum permissible distortion is 4 thousandths. Milling 30 thousandths off is just crazy. You would then expose the valve seats..

Now, you could have the flycuts in the pistons milled an extra 30 thousandths deeper.

Now on the bolts...I assume you are repairing the block in the car. All rod and main bearing bolts are TTY and need replacing. Rod bolts are a dealer item only unless you buy new rod sets. Ditto with head bolts and the injection pump pulley to hub bolts.

If you pulled the motor, get new bolts for the motor mounts. Any bolt that is torqued to specification and then some fraction of a turn more is a TTY and needs replacing.

I am doing a partial on my 2000 ALH and have heard more than a few people telling me I need to remove the motor mount and replace the bolts. Well, the TB is nearly new 100k unit and the mounts are staying put.
 
Last edited:
Joined
Jul 26, 2005
TDI
Jetta, 2001, black
you miss read me - the gasket is 30 thous difference, I am not sure what was taken off the head yet.
 
Joined
Jul 26, 2005
TDI
Jetta, 2001, black
ok - just got word - he took .002 off the head face, with the touch up on the valves and seats it should be fine. back for a 2 hole gasket it is.
 

Keith_J

Veteran Member
Joined
Apr 12, 2007
Location
West
TDI
2000 Jetta MT
2001jettaTDI19 said:
you miss read me - the gasket is 30 thous difference, I am not sure what was taken off the head yet.
Before you slap that head on, measure ALL valve protrusion with the valves closed. Assume your block has piston protrusion of 0.0433". Add the highest valve protrusion and 0.0433". Subtract this sum from the gasket thickness. If the number is negative, you could have problems.

With new heads, valves are 20 thousandths off the head. 0.0433" + 0.0200" = 0.0633" The 2-hole gasket is 0.0642" so there is no problem.

Yes, the pistons have fly cuts for valves that are about 45 thousandths deep but there is a need for maintaining clearances.
 
Joined
Jul 26, 2005
TDI
Jetta, 2001, black
thanks for the information!!!!
I really appreciate the help.

I am sure I am not the only one here that can use the numbers.
 

bigtom111

Veteran Member
Joined
Sep 8, 2004
Location
Kentucky, USA
TDI
99 Beetle, 97 Passat, 03 Jetta
"you miss read me - the gasket is 30 thous difference, I am not sure what was taken off the head yet."

Look at the chart again. Those are 4 place imperial dimensions. You are looking at 3 thousands difference in the gaskets, not 30
 
Joined
Jul 26, 2005
TDI
Jetta, 2001, black
thanks - I got confused.. I see one of the entries is off.. it should be .0398 not .398.

so if they cut 2 thous off then maybe I should go with the larger gasket... I will be taking closer measurements this weekend.
 

Birdman353

Veteran Member
Joined
Sep 15, 2005
Location
SW MO
TDI
2006 Golf
2001jettaTDI19 said:
thanks - I got confused.. I see one of the entries is off.. it should be .0398 not .398.

so if they cut 2 thous off then maybe I should go with the larger gasket... I will be taking closer measurements this weekend.
Your right that image I posted is wrong, Im going to pull it so no one gets confused.
 

novusB

Well-known member
Joined
Jun 8, 2024
Location
Detroit, USA
TDI
2006 Jetta TDI
Does anyone know if they still make these manuals?

I have a 2006 TDI BRM A5, would definitely LOVE to have something like this.
 

slowandeasy

Member
Joined
Oct 23, 2015
Location
TAMPA FL
TDI
2003
Does anyone know if they still make these manuals?

I have a 2006 TDI BRM A5, would definitely LOVE to have something like this.
YES YOU CAN BUY THRU SEVERAL SOURCES, BUT TRY YOUR LIBRARY ONLINE VERSION AND BUY ME A BEER WHEN YOU IN TAMPA. $75 TO 275 RANGE.... OR FREEEEEEEEE!
 
Top