Re: 16V G60 - How to (Wizard-of-OD)
Quote, originally posted by John Doe »
I have a PG G60 8V,How do I convert it to a 16V G60?
Quote, originally posted by Not2Fast »
Taken from this
site:
PG - 1.8 8V G60 :
Compression Ratio =
8:1
Rod Length = 136mm
Wrist Pin Diamater = 22mm
Bore = 81mm
9A - 2.0 16V :
Compression Ratio =
10.8:1
Rod Length = 144mm
Wrist Pin Diameter= 20mm
Bore = 82.5mm
PL - 1.8 16V :
Compression Ratio =
10:1
Rod Length = 144mm
Wrist Pin Diameter= 20mm
Bore = 81mm
According to the information posted above your going to have to get a set of custom pistons.Bahn Brenner sells a set of custom pistons for
$699.95US
Or you can contact
Rodney Huss for your custom application.
The reason you will need a custom set of Pistons is because placing a 16V head on an 8V Block lowers the CR approx 1.8 Points.Since the G60 engine is allready @ a CR of
8:1 then dropping that CR
1.8:1 points lower will bring it to about
6.2:1,definitely too low for a
16V G60.
Now for the Conrods you can use your stock
PG G60 rods but it is recommended that you use
PL 16V Rods + Custom Pistons due to the fact that your rod ratio using the PG rods will be too short.
Now that the pistons and Rods are out of the way your going to need the obvious:
1. 16V Head,Either 9A or PL.9A has bigger Intake Ports.
2. 16V Lower Intake Manifold.
3. 16V Scirocco Upper Intake Manifold (pictured below)- This enables you to relocate the Throttle Body from the passenger side of the engine bay (LHD) to the drivers side of the engine bay.You can then still use your stock G60 filter box.
4. Distributor
Now you have
2 options for the Distributor set-up.
1.
Quote, originally posted by Distributor In Head »
1.16V Distributor, complete
2.16V Distributor Block off plate complete
3.16V oil pump, complete
4.16V Secondary shaft and gears complete
5.16V Timing belt and gears, complete
6.16V Exhaust Manifold or 16V Header
2.
Quote, originally posted by Distributor In Block i.e. Retaining the PG setup »
1. CAM GEAR:
16V Cam Gear
Stock
20V/16V Cam Gear has
52 Teeth
2. CRANK GEAR: 16v crank gear STOCK but an ABA crank pullye shaved 5.5mm with a new centering ring pressed in.
Scirocco20v mods them for $10 if you supply it.or you can do it yourself.
Stock
8V Crank Gear has
22 teeth
Stock
16V/20V Crank Gear has
26 teeth
3. INTERMEDIATE SHAFT GEAR:
Combination of a 16V Cam Gear and an 8V Intermediate shaft.dont mod the gear...Mod the keyway in the IM shaft to fit the gear. The 8v used a press in half mood key way and the 16v cam gear uses a molded in 1/4 moon. It wont fit unless a path is cut in the IM shaft to fit the key on the gear to.
If Building
PG 16V Combination - Use PG IM SHAFT
If Building
ABA 16V Combination - Use ABA IM SHAFT
4. TIMINT BELT:
16V OEM Timing Belt
Your Physical engine should be done @ this point.
Quote, originally posted by John Doe »
I have a 16V and I want to make it a 16V G60,what do I do?
First the Compression Ratio of either the
9A or
PL needs to be decreased.As stated above the 9A and PL have a CR of 10.8:1 and 10:1 respectively so you can either machine/dish the pistons to lower the CR or get a set of custom 83mm units.Below is a picture courtesy of OttawaG60 showing machined
9A units.
Now that the internals are dealt with,your going to need quite a few parts off of a PG G60.John Doe...meet John Betz
Quote, originally posted by John BETZ »
G60 G-Lader Supercharger or BBM Screw Compressor Supercharger kit
G60 G-Lader mounting brackets and belt tensioner complete
G-Lader outlet (silencer box) or BBM RSR outlet kit
Quote, originally posted by John BETZ »
G60 Serpentine / idler pulleys for water pump and alternator
G60 AC pump or European water pump pulley
G60 Throttle body, complete
Coolant flange so that the outlet pipe does not hit the Charger.
Throttle Body Adapter to enable clearance issues with Distributor in head.If you use the Distributor in the block setup.all you will need is a Peugeot distributor cap.
Quote, originally posted by John BETZ »
G60 Fuel Injectors and FPR
G60 Idle stabilizer valve (ISV)
G60 Digifant1 ECU and engine wire harness
G60 Digifant control relay
G60 Oxygen sensor
G60 Water temperature sensor (blue)
G60 CO% potentiometer
G60 Relays, fuel pump
G60 Intercooler, IC hoses to and from the G-Lader
G60 Lower water pump pipe
Upper and lower coolant hoses
G60 Radiator and fan assembly
Quote, originally posted by John Doe »
Ok,now that I have a 16V G60,what do I do for my intake?
You have 3 Options:
1.Scirocco 16V Upper Intake to place the TB On the drivers side.
2. Audi S2 3B Intake Manifold chopped and modified to suit shown below.
3. Modify your upper Intake manifold resemble what you see below
Quote, originally posted by John Doe »
I want to retain my AC,Do I have to relocate the Alternator?
Yes,Lucky for you Bahn Brenner has an Alternator relocating kit.
Quote, originally posted by John Doe »
What about tuning?Can I retain my Digi-I?
Yes you can,
SNS Tuning seems to be the most favourable choice when it comes to Digi-I Chip Tuning and they can make a chip application for your 16V G60.
If you want to drift away from the whole distributor/chip set up then you can go with
TEC3 from Bahn Brenner
or
Stage Ic from 034EFI
Hopefully if everything works out as planned you should obtain this Courtesy of John Betz @ Bahn Brenner Motorsports
This is the original from VW:
And this is one in an engine bay
Special thanks goes out to:
OttawaG60,JBETZ and anyone else that allowed me to use pictures/info from there sites. http://****************.com/smile/emthup.gif
Please feel free to add any information possible as I am sure I left out of some.