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Sure, I'm 20 years late to the party, but it should be fun!
I've been lurking here and on other forums for a while. I'll be using primarily information from these threads along with a mix of other sources including eclipse and DSM forums. Old News!! 4G64 Swapped Into A 2002 Lancer DarkMitsu's 4g64 Swap Page
It gets tricky to sort information relevant to my situation when looking on DSM sites, but it's been more helpful than harmful, I think.
Initial thoughts and vague plan
Since I've never fully rebuilt an engine before (always bought long blocks), I'm gonna take it mild on this first round. I'll keep the car NA for a bit, but build it with forged internals for potential boost later on. I considered destroking to get higher revs, but since it's not necessarily going to be turbo any time soon, and not stage 3 or anything crazy, that seems unnecessary. I'm considering trying to source a 4g63 head, but not certain whether that should also be put off. I appreciate anyone's input or suggestions. And if anyone is selling parts, PM me please!
My car is an '03 Lancer OZ Rally with about 160,000 miles. Been a tank and needed very little maintenance or repairs over the years. The front crank seal started leaking recently, and I've been noticing some loss in compression, so rather than replace with the same engine I figured it's time to have some fun. In addition to the engine I've been repairing neglected suspension and other components: new ball joints, new struts front and rear, new bushings, new tie rod ends and so on. I need to replace the wheels because the beads don't seal well due to corrosion, and I'm having a heck of a time finding nice wheels in 4 lug that don't cost a fortune, so I'm thinking of doing a 5 lug conversion and converting the rear to disk brakes. I figure it's a good idea since it might eventually be turboed. Been looking at this for over a week now, and I'm stoked it's finally happening!
Decisions made: Final Plan
The plan is now to build the car in phases. Since it's my daily driver, this will allow me to keep the downtime minimized. Phase1 is the simple 4g64 swap, keeping the SOHC head. Phase 2 (who knows when) is DOHC head and mild boost turbo.
Phase 1:
The engine I bought is in such good shape, I've decided to probably not rebuild the SOHC head.
Teardown the 4g64 block
Machine shop will inspect, clean, and bore 20 over if necessary.
Machine shop will tap oil return holes so they can be plugged in phase 2.
Machine shop will inspect, clean, and deck the SOHC head.
build the 4g64 block for durability when eventually turboed, forged pistons and rods.
swap transmission gears
complete the 4g64 swap (lol, That's a lot for one step)
Phase 1.5:
Other upgrades that probably need to get done before phase 2
CAI
5 lug and rear disk swap (completed September 2025)
Phase 2:
Longer process, more prep. Getting the DOHC built and sourcing other components while also figuring out how to tune.
Pull Hyundai DOHC head from junkyard
Teardown head
Machine shop will inspect, clean,
Machine shop will tap head for Turbo oil supply
source parts: the new cam reluctor and bolt, better valve springs, turbo camshafts, intake and exhaust manifolds, turbo parts, aftermarket ECU?
build head, plan turbo install
zoom zoom!
Still need for phase 1:
Evo ECU
Eclipse trans
Donor lancer trans so my car isn't out of commission for forever
Slave cylinder
4g64 MAF sensor
custom motor mount bracket
exhaust manifold/header (donor engine one cut by Cat scavengers)
miscellaneous hoses, filters, gaskets
Parts: (will edit to add more as they are purchased)
So I also have a OZ rally that is in need of a head, maybe a block as well. Piston No. 1 is mangled and mashed and the sidewalls are scored slightly. Could i just sleave that one cylinder and get new rings and a piston? i may just get an entire kit and use what i need.
Any ideas or suggestions on what i should do?
So I also have a OZ rally that is in need of a head, maybe a block as well. Piston No. 1 is mangled and mashed and the sidewalls are scored slightly. Could i just sleave that one cylinder and get new rings and a piston? i may just get an entire kit and use what i need.
Any ideas or suggestions on what i should do?
Do you have the original engine in your OZ still? Sounds like you lost a timing belt, eh? I could sell you my 4g9 when I take it out, could be more than a month or more away though.
i think it would probably be cheaper to find a used engine in good shape than to pay a machine shop to sleeve it. I havent done any research on the 4g9 engines though.
This is gonna be sick! I have a buddy that has a ralliart wagon doing a similar setup as yours
Thanks! I'm super excited. I'm having a hard time reigning myself in. Part of me wants to get the stage 3 cams that are on sale from crower and go whole hog...
I already drive like an @55h013 though, wouldnt be good for me to have that much power.
Do you have the original engine in your OZ still? Sounds like you lost a timing belt, eh? I could sell you my 4g9 when I take it out, could be more than a month or more away though.
i think it would probably be cheaper to find a used engine in good shape than to pay a machine shop to sleeve it. I havent done any research on the 4g9 engines though.
Yeah i still have it. its impossible to find a running 4g9 motor. and i cant seem to find any videos, diagrams, or pdfs regarding on how to do any sort of engine swap. I may just sell it. I cant work on it either cause i have no money to work on it in the first place.
Lots of things to think about. I saw what great shape the engine is in. I read about how the SOHC head creates better compression that is better for an NA setup, and that I'll probably lose power, especially on low rpm using the DOHC head NA, I wanted to leave the SOHC head on until I actually decide to go turbo. The problem this brought up is that I want the machine shop to do the plugging of the oil return channels rather than using freeze plugs. But if the SOHC head is staying on, the holes can't be plugged, so I'll have the machine shop tap the holes and i'll keep the plugs on the shelf until I need them.
The plan is now to build the car in phases. Phase1 is the simple 4g64 swap. Phase 2 (who knows when) is DOHC head and turbo.
Suspension issues (busted bushings) and brakes forced the 5-lug swap to come sooner and be prioritized. 5-lug swap went pretty smooth once I got all the parts together. Took a while for a ralliart to show up in my local u-pull.
Here's a link to a picture in case the forum drops the image... (https://i.imgur.com/wjAecnU.jpeg)
17 x 7 koenig lightning wheels. Cheap 215/45-17 tires from tire rack.
Only real issue (besides seized bushing bolts that had to be cut out) was that the emergency brake cables have their mounting clips in different locations than where mine were. I'll need to zip-tie them up.
