http://www.kompressorkanada.ca/howto/16vG60.htm

16vG60 Conversion

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READ FIRST - This is by no means a complete how-to on a 16v g60 conversion. This is just advice and guidance. We are not legally responsible for the information that is contained here. If through the process you come up with any further advice please forward it to us so that we can add it to this list.
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The best source of info on this conversion is the 16vg60 group on yahoo http://autos.groups.yahoo.com/group/16vG60/
I'm going on the assumption that you have a 16v (with alt, dist, exhaust manifold) and a G60 engine with charger, bracket, tubing and digifant)

Parts needed

1) alt doesn't fit in stock location. You have to options here, under the G60 or on the back of the block. I chose to do it under the G60, I recommend doing in on the back of the block, it's a real pain in the arse to try and get in under the G60, there is no room. You will need 2 mounting pieces for the back of the head/rear motor mount. Here are the specs for one of them, the other just comes straight up from the rear motor mount.

2) With alt in different spot, serpentine belt needs changing. With alt under G60, you need an idler pulley between waterpump and alt to get grip on the waterpump (belt goes right across from crank) and you can use a 8v timing belt tensioner for tension, mounted where the old tensioner swing arm used to be.

If you have the alt on the back of the block, then you just need to make a small bracket to hold the tension spring in it's new location.

3) Crank pulley - G60 timing gear is narrower than the 16v one and offsets the G60 crank pulley. Get an 2L 8v crank pulley and get it shaved 6mm.

4) waterpump pulley - get one from a G60 Passat with no AC, fits there perfectly.

5) Fuel rail and injectors. You'll need an aftermarket fuelrail *available from Kompressor Kanada*. Get some #30 Bosch redtops to fuel the car. You will also need G60 injector inserts to put into the intake manifold.

6) Scirocco 16v intake manifold is a must.

7) Digifant - need to get custom chip, talk to Dave at KK, he does SNS chips here in Canada and they can cut you a 16vG60 chip with 30# injectors. You will also need to change the watertemp sensor, I have the part number somewhere. Make sure that you can mount the CO pot into the upper IC tube. Digifant MAP vacuum tube MUST be 1 metre exactly.

8) Intake elbow - custom part, I have a diagram for one, needed to clear distributor.

9) recirc tube, needs to be shortened...although I recommend removing it altogether and capping the charger off.

10) coolant hoses - mix and match of G60 and 16v, upper rad hose needs to be lengthened. If going into Mk2, 16v set should work fine as motor came in that car.

11) Compression, 16v engines have way to much for forced induction. I used stacked gaskets, you can either use forged pistons or a KK provided ABA metal gasket.

12) Spark plugs, Bosch F5DSR or F5DP Plugs.

13) Crank case breather in is now in the block, not the head, so you'll need to route that.

14) Block need to be drilled for G60 oil return line.

15) put in an A/F and boost gauge to round out the swap.



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