You can't just cap off the return line, your pressure is probably regulated at the rail, not at the pump like in a USDM Ralliart. Our fuel pressure regulator is built into the fuel pump assembly inside the fuel tank.

Perhaps an Evo fuel rail would work? I've never seen it in person, but I've read about people using the Evo rail and fpr in a RA, and adding a return line.

 

I'll just have to get more ralliart parts it seems. Probably delay me another month or two.

I didnt expect this hurdle because the USDM 04-06's are returnless, so I expected my 05 to be, but it isnt.

Anyhow, Im determined to find a solution, most probably my buying all the fuel parts from the ralliart.

 

I noticed on my shop manual for the ralliart, it shows an unused return line going from the tank to the engine bay. This is used on the return system but not on the ralliart.

This means that it should simply be a case of getting the fuel pump/regulator.



On my car that second tube goes to the fuel rail also, on the ralliart shop manual it connects to nothing.

(Thats a 03 shape lancer, yet its from the 04 ralliart manual!)

 

there are returnless systems, but im not sure if the ralliart has one!?!

 

I am not an expert for this but if you have a return fuel line already set up in your car then I would leave it in the car and just connect it up to a fuel rail that has the capeabilities for this... I believe that the Evo 8 and 9 fuel rails are very compatable with the 4G69 engine

It is funny really because here you are wanting to get rid of your return line were as I am wanting to put one in mine

any after market fuel rail for these cars will do - I have actually heard that even the stock fuel rail has the connection on it to accecpt a return line but I am unsure as to how true this is

O2 sensors... we have fitted the Haltech E8 to my car and are in the final stages of having it completed not sure if you are keen or not but with this ECU we are using it as a piggy back not as a full ecu replacement... the benifit with this E8 is that it will not need any of the O2 sensors

David from RPW might be able to help you out a bit more with questions in regards to this as the MV readings from your stock 4G94 will be very different from the 4G69 requirements so it could mean that you will have to replace all of the wiring harness or opt for the E8

 

Well the engine is damn near complete now, just waiting to get the RRM Clutch and Piggyback ECM.

I've decided to do the engine install myself with a mate of mine - Reason being twofold, firstly Its been a project of mine for a long time, and I'd like to do the final stages myself. Secondly, I have a huge knowledge of the car and engine now, and I feel it would be better for me to supervise the installation. My mate is an engineer so everything should go OK.

More importantly I'll save myself a fortune and have it done in less time! We've got the shop manual so it should be simple.

I'm expecting to do this in early september realistically.

 

did you consider trying to do an FTO swap?

 

Nope. Only considered the 2.4 coz its a straight swap, and meant for the car.

 

That is alot of $$$$ and hard work to get that motor in there. Props to you man for having the patience, I know I wouldn't.

 

yes, try FTO swap... V6 engine....NA power, not too bad! I think it might be easy to do....at least it's about direct bolt on for older model of Asian Lancer (95-00) & Mirage.....

 

Problem with engine swaps is most people dont consider what really needs to be done - its not a case of buying an "engine" and mounting it... Infact most breakers wont included half the parts on the engine that you need - I spent a lot of time finding good condition ps pumps and ac compressors, along with various clips, wiring, relays, etc

 

cant wait to see this thing on the road !!!!

 

Well, every part has been bought for the swap now, so I've been able to tally up the exact cost. This just puts into perspective how much an engine swap costs. Bare in mind all of these things are vital for the swap - you cant just buy an engine and expect it to fit. If course I've spent a lot of money on RRM's line-up - nearly the whole lot! So that has increased the cost greatly.

Heres quick timeline. I've still yet to add on the flywheel and clutch because the A/T crank bearing is difficult to get out!



Anyhow, heres what I've spent over the past year, and now were finally ready. We are using the 4G18's transmission, only difference being a lower 4th and 5th ratio. Most of the 'extra' parts were used, however some are new.

4G69 Engine Almost New $3240

Starter Motor $50
Alternator $75
Flywheel $469
Flywheel Adapter Plate x2 $10
Flywheel Crank Bushing $3
Flywheel Bolts x7 $8
Air Conditioning Compressor $200
Air Conditioning Compressor Bracket $30
Power Steering Pump $100
RRM Crank Pulley $129
Engine Rear Cover $15
RRM Intake Manifold $349
Phenolic Spacers $189
MAF Sensor $50
Injen Cold Air Intake $270
AEM Bypass Valve $40
RRM Stage 1 Clutch $459
Power Steering Oil Cooler Tube $10
Oil Cooler Tube Clips $5
Throttle Sensor and Cable $50
Control Wiring Harness $200
Battery Wiring Harness $50
Fuel Pump $75
Engine Control Module $250
RRM Piggyback $459
Flywheel Housing Cover $8
Right-Hand Drive Axle Assembly $125
RRM Header $499
Exhaust Manifold Gasket $20
Starter Motor Cover $15
RRM Cat-Back $459

Total Extras: $4671 Not including shipping
Total: $7911

Also, on a different topic, Accolade told me that my Evo IX style front bumper is ready to ship, and sent me a photo of it in its box - seems they are improving their customer relations greatly - I even notice the bumper is their far superior "non-yellow" material that my rear was made off, which turned out perfect. So I'm looking forward to that much nicer Evo IX grille!

 

Now that is what I call packing.... your car is coming along slow and expensive but hey that is what modifying is all about especially when the engine just does not exist in your country you have done an outstanding job in all areas from locating parts to putting it all together

 

nice timeline, lookin forward to seeing the further progress