craziscot wrote:Storm Developments are offering an R36 conversion now as one of their regular services.
They had two brand new R36 lumps waiting to go into cars when I picked mine up, very sweet looking piece of kit!
So I (secretly!) got to the point of actually buying an R36 engine and spent a lot of time researching what needs to be done to get it to fit, including spending a good amount of time talking to Storm.
Sadly, the whole project was looking like it was going to cost in the region of £5k to get running and involve a whole world of unknowns. That could have been ok, but you're only realistically looking at 50-80hp more than the Mk4 R32.
DifferencesFirstly, the new generation VRs are 10.6 degree V, not 15 as per engines of old - this makes the engine slightly longer and taller. They are all (so far) mounted longitudinally in all cars you can buy them in and have slightly different mounting points.
Most importantly - the engine runs on FSI which is a direct-injection system similar to that used by diesels.
Physically fitting itYou can probably get the engine to physically fit in the car - Storm have had one running in a Mk4, but it will involve custom engine mounts and you are likely to have issues with the additional height of the engine. It looks like you can probably bolt the standard VR or 02M gearbox up to the engine (same stud pattern), but as the engine is a different size, you'll also need custom drive shafts. Similarly, as you're now mounting the engine transverse, you'll definitely need a custom downpipe and ideally manifold too.
These problems can probably be overcome. However, the really difficult bit is the engine management. Due to this FSI lark, you have the following options:
Run it stockTo do this, you'll need the engine, ECU, loom, clocks, ignition barrell and all 12 or some silly number of lambda probes, including the dual-cat system. Again, as all of the current engines are mounted longitudinally, the exhaust won't fit, so you'll need to modify it, making sure that you maintian all the probes in the right distances along the pipework.
Run it on aftermarket managementNothing currently exists to do this. You need 100V range voltages to operate the high pressure fuel rail, then 100A range current to fire the injectors. Not to mention a completely different set of timings than a traditional manifold injection engine. The Storm boys say they're developing an ECU to do this based on Emerald, but speaking to Dave Walker at Emerald he's not got time to even start on it at any point in the forseeable future. I think Storm have started looking for components to drive the thing, but it's all going to be very experimental and very, very expensive - sounds like in the region of £3k+ for an ECU.
Swap the manifold and run it as a conventional injection system on aftermarket managementYou can swap in the inlet manifold for a conventional one and the use an aftermarket ECU to run the engine. Problem is - no inlet exists, you'd also need to make/find a fuel rail and also buy an aftermarket ECU. On top of all that, you'd likely get slightly less power out of it, so you'd end up with something that's not much more powerful than a standard R32.
So as you can see it's not a very simple or cheap task to undertake at the moment. Having said that, give it a couple of years when someone has devised an after-market ECU to drive FSI (and interestingly the same thing could probably be used to drive an after market TDI) then it'll be a fairly easy task.
If you're still game then I've got details of a guy who was selling brand spanking new, never fitted to a car 3.6 engines from a Touareg (BHK engine code) for £1500 but they are just the basic engine, so no alternator, PAS pump, exhaust manifold, etc...