I swapped my 12v and I have been making a list of stuff I needed. Since you have a 24v its significantly easier. I'll try and remember to tailor up my list and post it, but you're on the right track. Like you said most the info is out there its just in a million places and there's no good list.

No 3.2L VR6 is direct injected to my knowledge, that came with the 3.6L. You can use any 3.2L, but some of the later ones (Mk5 R32, 08 Audi A3, Eos, etc.) have more exhaust cam adjustability and I don't think the Mk4 ECUs like that. Could be wrong though not 100% sure if that's something that can be tuned in or not.

 

Alright here it is. I wrote this from my perspective of swapping a 12v VR6 car with a Touareg 3.2 (far cheaper than sourcing an R32 engine, but they're the 99% same thing internally) so there's definitely some material in here that isn't relevant to you.

• 12v/24v Passenger Engine Mount Bracket w/ Bolts
  • There are two part numbers for this 1J0199354F and 1J0199354H. It seems the first is for 12v/2.8 24v and the second is R32? Regardless, the parts look identical as far as I can tell and I had no issue using the bracket off my 12v.
• 24v accessory bracket and belt
  • R32 and the 2.8 24v use the same bracket here (022260087D). The design of the 12v bracket is completely different and won’t work. Also note that the belt lengths slightly different going to 24v (AC: 066145933J, Non AC: 066145933K). Accessory components like the alternator, tensioner, and power steering pump will transfer straight over. Can’t confirm if AC compressor fitment and lines are the same as I deleted mine long ago.
• 24v crack pipe
  • Not sure what the exact difference is because they look similar, but they are different.
• 24v thermostat housing and rad return elbow
  • The thermostat housing (022121117C) from the Touareg is actually the same and can be used, but the rad return elbow is pointing a different direction. To make your life easier you want the 24v version which is 022121121E.
• 12v/24v Coolant temp sensor
  • The Touareg coolant temp sensor (the one installed in the thermostat housing) is a 2-pin sensor and the Jettas/Golf have a 4-pin sensor so you can get a new one or reuse the one off your existing Mk4 VR6 they’re all the same.
• 24v Crank pulley
  • Technically I believe you can use the Touareg crank pulley, but it is setup for an extra rib in the belt which will be unused with the Golf/Jetta belts. I simply got one off a 2.8 24v/R32 (022105243A). The 12v part number is different (021105243D) and I did not try to see if it would work, admittedly they look very similar visually. When I pulled the stock Touareg one off there was a shim installed there on the crank… I don’t think I reinstalled it with the 24v pulley. Really weird because it’s pictured in ETKA diagrams and noted as part “4A” (and “4” being the crank pulley) for every VR6 car I looked at (Mk4, Mk1 Touareg, Mk3, Corrado) but not listed as a part so I have no idea what the purpose or part number is.
• 24v lower timing cover or shaved Touareg
  • The Touareg lower timing cover interfered slightly with mounting my 02J, and I suspect it would for 02M transmissions as well. You can get a 2.8 24v lower timing cover (03H103173). I think you can probably use the one off a 12v (071103173B) as well… again different part number, but they look identical. Or you can simply get your favorite grinding device out and shave the Touareg cover like I did as pictured here.
• 24v Exhaust manifold
  • The exhaust manifolds are completely different from the 12v design, and the Touareg ones won’t work unless you are fabricating your own downpipe. 2.8 24v/R32 ones are the same part (022253033M, 022253034M). You’ll naturally need the corresponding gaskets as well.
• 24v downpipe
• 3.2 Intake Manifold Heat Shield
  • You can get away with the Touareg one with the 24v exhaust manifolds, but its tight and not ideal. Getting the heatshield off a transverse 24v car is more ideal, but somehow I ended up getting one that still didn’t fit perfect. I think it was off a 2008 Audi A3.
• 12v/24v Oil Pan and Pump
  • Pretty self-explanatory here the Touareg pan and pump are completely different. Unless you really want to reduce your oil pan to ground clearance by a solid 2-4 inches I would swap them. Any VR6 pan/pump combination works (excluding 3.6L).
• 24v Oil Filter Housing
  • Touareg oil filter housing doubles as an engine mount and won’t work well in a transverse car. So, you’ll need the 2.8 24v/R32 oil filter housing (022115403R) and an oil cooler setup. The large Touareg oil cooler can be reused with Mk5 R32 coolant lines (022121049G), you can bolt up the smaller R32 setup, or use the 24v 2.8L setup which is smallest (same oil cooler as the 12v, different coolant lines).
• Mk4 R32 fuel rail assembly or Mk5 R32 fuel rail and filter
  • The Touareg utilizes the same injectors as the Mk4 R32, but the fuel rail is returnless and setup for longitudinal feeding meaning you would need to run the fuel line around or across the top of the engine. The solution is do what I did and convert to a returnless setup (Mk4 2.0’s already are), purchase a Mk5 R32 fuel rail (022133317M), and fuel filter (6Q0201051J). Alternatively, get the rather expensive Mk4 R32 fuel rail.
• 24v Coolant Hoses
  • This can get rather complicated depending on what you want to keep or delete and what some of your other build choices are, but not all coolant lines from the 12v are a direct swap. I changed out all, except for the reservoir feed and return, for 2.8 24v ones. You can also opt for R32 ones for reasons such as keeping the auxiliary radiator (2.8 24v cars did not have this, unlike 12v cars).
• 3.2 Intake Manifold
  • Can use the Touareg intake manifold, or source one off any other 3.2. Mk4 R32 intake manifold requires the Mk4 R32 valve cover and PCV tube setups.
• 3.2 Throttle body
  • Can use the Touareg throttle body, which does not have coolant ports so its nice and clean in that regard. Or you can use a Mk4 R32 one with the coolant if desired.
• Mk1 TT 3.2 Intake Flex Tube
  • Accommodates the larger throttle body and MAF housing. It is slick without PCV port, which is unused on a Mk4 R32 Intake Flex Tube with the Touareg PCV setup.
• Mk1 TT 3.2 airbox or Mk4 R32 airbox (ridged top, clocked MAF 90°)
  • Accommodates the larger and clocked differently MAF housing.
• Mk4 R32 engine harness
  • The 24v harness can be used alternatively, but the coil wires route a little differently.
• 24v O2 harness
  • Can use an 2.8 24v or R32 one. The second bank of oxygen sensors is simply left unused for an R32 harness.
• 24v ECU Tuned
  • I went with a UM swap tune for mine.

 

• Mk4 R32 fuel rail assembly or Mk5 R32 fuel rail and filter
  • The Touareg utilizes the same injectors as the Mk4 R32, but the fuel rail is returnless and setup for longitudinal feeding meaning you would need to run the fuel line around or across the top of the engine. The solution is do what I did and convert to a returnless setup (Mk4 2.0’s already are), purchase a Mk5 R32 fuel rail (022133317M), and fuel filter (6Q0201051J). Alternatively, get the rather expensive Mk4 R32 fuel rail.

This is great info. I've been trying to validate this for some time now as I'm doing an 04 R32 BJS swap in my MK1 and would rather do a returnless fuel rail and have the filter do it neat the rear by the Fuel Cell.

Is there a difference to the variations for the VR6 3.2L Fuel Rails that are returnless? I see variations of the Modification Code (022133317M) for same Fuel Rail (AB, J)

Thanks!!!

 

I don't know honestly, I would suspect any differences are almost unnoticeable.

 

I think I figured out the Letter at the end. I'm looking for a fuel rail for a BJS 3.2L and want to go returnless for the fuel. 022 133 317 M is the one I want off the BUB, but came across one from a Toureg which ends with J. The inlet fuel line is on the other side of the rail K is the MK4 one that I originally have, which has the fuel return on the rail So part # seems to be compatible, but the Letter will be the Variants. Thoughts?