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Mark's 3.6 Varioram transplant

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As some of you already know, I have intended to transplant a 3.6 Varioram engine into my 3.2 for some time. I have even had such an engine sitting in the corner of my garage for some years. I have also collected most of the other components needed, but I wanted to sort out the bodywork and suspension first and most importantly drive the car! Two other factors that have delayed it are my notchy 915 gearbox and a great running 3.2. I now have a spare late model 915 that I will be getting rebuilt and upgraded this year and I have found some time to do a few pre-transplant jobs to the engine which I thought I should report on.


Please don't get too excited about wanting to read about the completed swap an time soon, this will be more of an occasional update thread as I am not in a great hurry, the car is driving great and the 3.2 is running strong.


Background


The engine I have is a 1996 Varioram engine from a 993 manual Cab. The engine was upgraded in 2004 with Cup Cams, solid lifters and a remap by JAZ and I have copies of all the receipts for the work. Sometime later the owner of Hayward & Scott Exhausts bought the car and later swapped the engine for a stock one as "it was a bit too lively for a pensioner". The engine was stored in their workshop until purchased by another IBer, Chris/Anconablue72, for a swap into his brown SC. Chris had a change of direction and I took the engine off his hands. Neither Chris nor myself have seen the engine run, but I have spoken to a couple of independent people who knew, and lusted after, the engine just before it was removed from the 993 Cab.


Am I going to lucky and eventually start a strong engine, or face a costly rebuild? :wacko: We will have to see, but you have to take some risks in life. :D


The engine...
vram1_zpseb983e26.jpg
vram2_zpsfaa3ac18.jpg
vram3_zps836612e1.jpg
Some conversion parts from Patrick Motorsport, which stimulated some security interest when in my hand baggage!
vram4_zps7727f173.jpg
The elusive DME to engine loom which did not come with the engine, it needs some work to eliminate extraneous wiring spliced in for an alarm system.
vram5_zps0942d9d7.jpg
To be continued...

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Nice one Mark, great that you've finally come out :D

 

The VRAM looks great & I think your car will be a bit special with all that extra power!

 

First dibs on your old gearbox as I'd love to be able to do what you're planning i.e. rebuild the 'box without the car being off the road for ever.

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Top stuff Mark, kept that quiet about it being a souped up 3.6, you dark horse! Your car will fly!!

 

Crikey what with jevs 3.6, longmans 3.4+ and now your 3.6 I will have no other similar 3.2 cars to play with on our track days anymore :( need a windfall so I can plump an extra 50 horses in ;)

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Top stuff Mark, kept that quiet about it being a souped up 3.6, you dark horse! Your car will fly!!

Crikey what with jevs 3.6, longmans 3.4+ and now your 3.6 I will have no other similar 3.2 cars to play with on our track days anymore :( need a windfall so I can plump an extra 50 horses in ;)

His 3.2 made similar numbers to mine at AMD mate , I'd be first in line for that ....

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Nice one Mark :)

 

Look forward to seeing the progress over time.

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Nice mate!

 

You gona do the single pulley mod? Also you will need a different air outlet cowly thing if you want to use the RS heat bypass tube.

 

Be good to see some pics of the non AC bracket(assuming its not just been hacked?) Also whats the funny shaped black pipe between the breather pipes and the fuel rail in pic2?

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Don't worry MarkJ I still have a bogo standard lowly 3.2 you can play with.

Just thinking out loud and a genuine reason for asking.

Why go to all the hassle and expense with the installation of a 964 or 993 engine.

Surely a decent set of cams and 3.6 or 3.8 litre barrels and pistons would reap similar rewards on a 3.2.

For out and out power I don't think the varioram system is the answer on a 993 engine, the RS's did not have it and I believe most never made the 308bhp (from memory) that they were supposed to anyway.

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longmans 3.4+ .............

 

I know i'm not around these parts much anymore but did I miss something....

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Nice mate!

 

You gona do the single pulley mod? Also you will need a different air outlet cowly thing if you want to use the RS heat bypass tube.

 

All will be revealed in the next instalment!

 

Be good to see some pics of the non AC bracket(assuming its not just been hacked?)

 

Here you go...

IMAG0461_zpsfe69d0ae.jpg

IMAG0463_zpsa21dff95.jpg

 

Also whats the funny shaped black pipe between the breather pipes and the fuel rail in pic2?

It is the bellhousing to air filter vent that is just sitting there loose, evidently used to clear fumes from the clutch area on a 993. I will be going in the bin.

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Surely a decent set of cams and 3.6 or 3.8 litre barrels and pistons would reap similar rewards on a 3.2.

As far as I know you can only enlarge a 3.2 to 3.4, or 3.5, which is expensive and really needs twin plugging and 3.6/3.8 barrels will not fit. A 3.6 comes as standard with twin plugs, knock sensing, etc.

 

 

For out and out power I don't think the varioram system is the answer on a 993 engine, the RS's did not have it and I believe most never made the 308bhp (from memory) that they were supposed to anyway.

Race cars did not have Vram, so I agree that for out and out power it is not the ultimate, but this is for a street car with the odd track day where the increased torque that Varioram gives is the main benefit.

 

The Varioram system was first introduced on the 993 RS in 1995, one model year before Varioram was introduced on the rest of the normally aspirated 993s in 1996.

 

Mark

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Installing RS single pulleys


Standard multi-belt set up with different speed drives for fan and alternator.
vram6_zpsb8119718.jpg


Bottom pulley and fan hub on.
vram7_zpsddd13d76.jpg


The RS fan hub is top left, the components on the right are discarded and the other pulley halves, adjuster shims and nut are reused.
vram8_zpsc06c4cf7.jpg


Top pulley on and the old bottom pulley resting in place for comparison; saving in rotating weight was about 1.25kg (850g from bottom pulley, 400g from fan hub and pulley) and there will be a reduction in parasitic drag from the alternator.
vram9_zpsdb489dce.jpg


To be continued...

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His 3.2 made similar numbers to mine at AMD mate , I'd be first in line for that ....

259.8 hp & 237.5 lb/ft - please form an orderly queue ;)

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Awesome news Mark!

 

So engine in the car by the end of the week and first track day next weekend!? :mad jg:

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Making an air feed for the heating.


Made a buck from scrap tube and body filler.
vram10_zps4bf7d647.jpg


Made a mould.
vram11_zps4a520e7a.jpg


The raw fibreglass moulding.
vram12_zps7e8b91f7.jpg


Finished, in place and with the distributor air feed fitted.
vram13_zpsfc9c2908.jpg


Mock-up of how the flexible tube will route over the top of the distributors.
vram14_zpsa863f44f.jpg

 


To be continued...

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Some brackets & studs.


Made a bracket for the vacuum reservoir, used light alloy as there is little weight involved.
vram15_zps4438af17.jpg
vram16_zpsd1335b0d.jpg


In place and connected up. The vacuum seems to hold and the Vram flaps operate when the connections in the loom are jumped.
vram17_zpsc4f9d2b6.jpg


The bracket to hold the air filter needed to be a bit more substantial and so I made it from sheet steel and when in the final shape welded overlapping joints.
vram18_zpsca0f39b9.jpg


Final product, painted and in place.
vram19_zps9526bfa5.jpg


Also changed the gearbox mounting studs and replace the oil seal.
vram20_zps366ba026.jpg

 

 


To be continued.

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Awesome! Is there nothing you can't/won't do?

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It is the bellhousing to air filter vent that is just sitting there loose, evidently used to clear fumes from the clutch area on a 993. It will be going in the bin.

 

Don't sling it Mark, I'll have that. :D

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Great work as usual Mark, but this surprised me:

259.8 hp & 237.5 lb/ft

as it didn't seem to have a significant advantage over my SC at Snetterton, and with those numbers I'd certainly expect it to

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Don't sling it Mark, I'll have that. :D

OK, I'll keep it for you.

 

Great work as usual Mark, but this surprised me:

as it didn't seem to have a significant advantage over my SC at Snetterton, and with those numbers I'd certainly expect it to

You are forgetting that you also have to factor in the Drive :whistling:

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Thanks for all the positive comments, here is some more...

 

Power steering block-off fitted, alloy panel to stop the cooling air leaking out made and fitted and oil pipes fitted.
vram21_zps126f2da1.jpg


Bracket to support the ends of the oil pipes made and fitted. I used heavy duty alloy with the bends formed hot to avoid weakening it.
vram22_zps006170bb.jpg


Slow roasted flywheel anyone? Heating up the conversion flywheel while the pilot bearing is in the freezer.
vram23_zps77f738f4.jpg


The bearing fitted into the flywheel with a light tap
vram24a_zpse129eaaa.jpg


Torqued into place with new bolts and Loctite 270 (I had previously checked it did not foul the engine case which can evidently sometimes be an issue).
vram24_zpsc07c58bc.jpg


Flywheel sensor did not have enough adjustment to get the gap correct, so ran a drill down each bore to give a bit more adjustment.
vram25_zps2fb7fe29.jpg


Gap set.
vram26_zpseb3f1381.jpg

 


To be continued...

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Inspiring stuff Mark, can't wait to get some time working on my 3.6. After reading your posts this evening.

Where do you reference the torque settings for the fixings on this engine?

What's 'Bentley manual' equivelant for a 964/993 engine?

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Where do you reference the torque settings for the fixings on this engine?

I have a copy of the 993 workshop manual. I can let you have a copy of the torque settings, but not all will be common with a 964 as some important components are different (e.g. the crank!).

 

Mark

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Thanks for the offer - where could I source similar for a 964? Is it download or hard copy?

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