From the diagrams below you can see the differences between a conventional return-type system and a returnless system. The return type utilities a pressure regulator after the fuel rail and the returnless system uses a pressure regulator before the fuel rail.
The LS engine does however operate at a different pressure and as result, demands more fuel. Because of this, we will need to run a different fuel pressure regulator and an upgraded fuel pump. The Porsche uses an integrated fuel pump and pressure regulator unit in-tank, this difference will result in some customization to get everything mated together.
Another issue we encountered, was that the clearance between the intake manifold and the top of the engine bay is extremely tight. To eliminate this, we will be looking into a Holley performance AN flanged fuel rail to eliminate the stock fuel rail crossover tube.
The time has come to test fit the engine and transmission in the Porsche chassis. We did the prep work on the engine, which included installing the clutch/flywheel and mating the LS3 engine to the Porsche transmission via an adapter plate. We then installed various components on the engine, such as the alternator and mount plates. The next step was figuring out how to test fit the compilation in the Porsche.
Since there was no way the engine was going to drop in from the top, we decided to put the engine/transmission on a steel work bench, and drop the chassis on to the engine.
After a few modifications, the engine fit pretty easily!
This project started because the owner of the 996 Porsche C4S came to us with a blown engine. It turned out that the cylinder walls were scratched badly, which caused knocking in the engine. The only way to get this car back on the road would be to rebuild the stock engine.The problem is that no one likes stock! Where others saw a problem, we saw an opportunity. We presented the options to the owner of a stock rebuild, or doing a complete LS engine swap. We had been in communication with a company in Las Vegas called Renegade Hybrids, who specializes in LS swap conversion kits for a variety of older generation Porsche vehicle. There are a few advantages of doing an LS engine swap vs. a rebuild.
- more hp, more torque
- similar costs
- GM factory warranty for the engine
- cheaper maintenance
- retains stock transmission
- increased reliability
- its a no brainer!
So after various discussions with the owner, he decided to go ahead with this project. So we ordered a 485hp version of the 6.2L LS3 in crate engine form, and ordered the necessary conversion parts from Renegade Hybrids. After that, it was just a waiting game for the parts to arrive!
Haute AG here, coming at you again with another project kickoff announcement! Hopefully you followed and liked our Project G35 LS build, now it’s time to announce our next Euro oriented build! Introducing Project BMW M3 Turbo. We will be doing a full custom Borg Warner turbocharger, along with an AEM Infinity stand alone ECU management system. We will take you through the build process with detailed pictures and commentary.
This vehicle originally started life as a simple yet clean BMW M3. When the latest owner got his hands on it, all of that quickly changed. The car was equipped with a wide body Flossman kit, bolt in cage, and an Active Autowerke supercharger kit. The car saw many track days, including a showing at M Fest. As it seems to go with all enthusiasts, however, the owner soon realized he needed more power. You can see the previous iteration of this car, in the PAS Mag Feature HERE and the Illmotion Feature HERE.
After the engine is this set up blew a piston, it was time to set ourselves apart, we chose to go with a custom top mounted turbo setup. Most guys with an M go with the HPF bottom mount kit, which are great systems as well. However we wanted to challenge ourselves, and be the first to successfully install the largest EFR series turbocharger Borg Warner makes, the EFR9180. So, after some careful planning we figured it should all fit, then we got to ordering a custom turbo manifold, along with an intake manifold and intercooler.
Stay tuned as we make headway through this exciting build, and bring you current pictures/descriptions as we transform this M into a turbocharged monster!