You cannot construct a new roadway without new catch basins. Additionally, because you are converting from an absorptive medium (grass and plantings) to a hard surface (asphalt) design checks would have to be completed to ensure the surrounding systems can handle the extra water. As smallspy said, in Toronto or any other urban city, you have to treat this as a new road and stormwater management is a big part of the cost.
This goes the same for adding a right lane for a BRT-lite setup. The storm drains will have to be moved, the entire pavement re-graded, and other site work. Sounds real simple, pave a roadway in an open field and it will be cheap, but these other issues must be accounted for and will increase the costs to some degree.
I consulted with one of the engineers at my office (good part about working in a planning/engineering office, haha), and he said that you could get away with ditches in some spots in Ottawa (a lot of the Southwest Transitway extension through the Greenbelt was done with ditches), but the standards in Toronto are different. He ballparked around $20 million/km for the new roadway, which isn't significantly more expensive than what I had quoted.
Sorry for the confusion, I was just looking at recent Transitway projects in Ottawa and I assumed the same thing would apply in Toronto.




