I wrote the KK link above, I'll add some info to this post.
|Quote, originally posted by Wizard-of-OD »|
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,Definately 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.
Easiest way to do this swap is start with a 9A, stack 2 ABA headgaskets.
Remember the G60 flows ~300-350 cfm, so the boost you get on a 2L 16v will be ~10 psi.
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.
9A has better exhaust ports, and for this application, it's probably the better choice.
IIRC not all 16v lower intake manifolds bolt up to the Scirocco.
If you plan to use the Scirocco and the Dist, you'll need an elbow to clear it as the recirc will interfere.
Stock 16v one is the way to go. Digifant will have no problems with it.
Coolant flange so that the outlet pipe does not hit the Charger.
This is only for Lysholms, I'm using the stock 16v one.
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.
There is a drawing of an intake elbow on the yahoo group (dougG60)
Yes,Lucky for you Bahn Brenner has an Alternator relocating kit.
There are also drawings of this on the yahoo group.
Or you can try and mount it under the G60.
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
I ran SDS with my engine, and am now working on MegaSquirt, 2 other options that would work well.
Crankcase ventilation, make sure you vent the valvecover and the front of the block, and use a catchcan, some 16v's seem to spit oil.
Corrado downpipe matches up with the 16v exhaust manifold, if you're in a Corrado, you can use that for exhaust.
Fuel rail and injectors, plenty of good 16v fuel rails out there, injectors, try Ford motorsport green (#42), they are bosch.
Don't forget the inserts (G60 injector for manifold)
I'll keep adding as I remember things I've come across during my swap.