doncarbone's OZ (4G94) to Ralliart (4G69) engine swap + 4G69 5spd Outlander AWD swap
 

2003 OZ Rally (4G94, automatic) --> 2006 Ralliart (4G69, manual)

Newer pic:
Attachment 332180

Before / After:

Attachment 333265

Finally decided to get a project build up. Some of you may have seen my Custom Car PC project which involves putting a 350W PC computer into the trunk of my vehicle and a custom fabrication for my dash which houses a 10.2" touch screen and volt gauges. I've come a far way with that particular project but through persistent daily driving, an old beaten up motor and general curiosity, I soon turned my attention to upgrading my car well beyond its interior.

Here's the car a few days before she was gutted:

Attachment 334659


My inspiration for this swap came from Diavlo's UK Lancer to 4G69 swap who thoroughly researched the process and did a great job describing some of the obstacles along the way. I'm hoping I can do the same thing and help anyone who owns an OZ/ES lancer perform this swap. All in all, it's an easy swap, just a lengthy parts list.



Disclaimer for those who think I should have just bought a Ralliart:

Diavlo does say that anyone with a perfectly good OZ Rally or Lancer ES from North America shouldn't bother doing this swap and all-in-all he's offering good advice. Diavlo converted a 4G18 1.6L UK lancer to the 4G69 as the Ralliart, at this time, was not available in Europe.

My situation is a bit different though for four reasons:

1. My 2003 OZ Rally, purchased for just $3,000 from an auto auction, had on it the day the motor was removed close to 265,000km. Radiator blown and motor leaking oil frequently. I didn't see it wise to rebuild that motor and start from the 120 or so horsepower that even an OZ rally in good shape has.
2. I had invested a lot of personal time and money fabricating my dash and constructing the brace in the trunk for the computer, amplifiers and subwoofer enclosure. I've grown very attached to the car over the years I've owned it, and I didn't want to sell it and buy a new one despite recommendations to just buy a used Ralliart.
3. To buy a used 04-06 Ralliart (stock) in decent shape where I live is about $10k-12k CAD. Given that I've performed the swap for under that amount + many of the stock parts are upgraded, I'm getting more 'bang for your buck' and a unique sleeper with strong potential for future turbo
4. I enjoy doing this and I wanted a new project

So far mostly everything fits - I'll get into the areas that did require custom work and I'm happy to answer any questions.


Parts needed for swap: - all from 04-06 ralliarts

4G69 2.4L powerplant (165hp), 95,000km - $1,200
4G69 5spd manual transmission 65,000km - $650
ECU (used)
Wiring Harness, included fusebox/complete, uncut (used)
clutch pedal assembly (used)
shifter cables (used)
shifter assembly (used)
brake/clutch cylinder (used)
clutch slave modulator (used)
throttle pedal assembly (used)
mounting brackets for alternator/PS (used)
throttle pedal sensor (used)
starter motor, 95,000km (used)
axleshafts, NEW
alternator, NEW
intermediary shaft (5 pieces), NEW
Full timing belt kit, NEW (included: timing belt, balance shaft belt, water pump & gasket, auto tension adjuster, timing belt tensioner, balance shaft belt tensioner, timing belt idler, accessory drive belt, valve cover gasket, spark plug tube seals, thermostat, camshaft seal, front crankshaft seal, balance shaft seal, oil pump seal
passenger side upper motor mount NEW (bolts up perfect to chassis but is different than OZ mount)
p/s pump (used)
power steering high pressure hose (used)
return hose from reservoir to p/s pump (used)
5spd brake pedal (used)
A/C compressor (used) all accessories from RA have 5 ribs, OZ is 4, will need either new accessories all together or different pullies
mass airflow sensor - oz rally MAF accepts 7 pins, RA only 4


Bolt ons:

Engine & Drivetrain

ACT Stage 3 clutch kit + throw out bearing
AEM short ram intake
Magnaflow catback exhaust
Clutchmasters aluminum flywheel
RRM custom headers/downpipe
RRM underdrive pulley
MIVEC ported/polished intake manifold
Megan Racing aluminum radiator
SAMCO radiator hoses (EVO 8)
RRM motor mounts
SPAL high performance radiator fans (12" and 7.5")


Wheels/Tires/Brakes:

16x7 Enkei RPF1
Bridgestone Potenza RE760 Sport
Wilwood Big Brake Kit & Flexline Kit (front only)


Suspension:

Tein basic coilover set
OEM Pillow Ball Mounts / Bearings
OEM suspension bushings replacement
Progress rear anti-sway bar
RalliSpec front strut bar
RRM lower tie bar
Camber/alignment kit


Body/Exterior:

[ ] Seibon EVO Style Carbon Fiber Hood
Accolade body kit (evo 8 spoiler, evo 9 diffuser rear bumper, evo 8 side skirts, K2 front bumper)
RRM evo style grill
DEPO euro style black taillights
DEPO euro style black projectors
Onex HID kit 6000k


Interior:

evo 8 steering wheel
corbeau A4 racing seats
carbon fiber overlays on a-pillars, shift console, middle console, wheel
evo 8 instrument panel/gauge cluster
(4) oem evo 8 floormatts
evo 8 shift knob
Autovation pedal set
Custom dash fabrication for 10.2" touchscreen LCD
kinetik hc800 power cell
stinger 300 amp isolator
griffin powermate
opus solutions PSU - 350W
computer (4gb ddr3, X2 2.4ghz cpu, 120gb ssd, creative x-fi sound)
focal 165a1 components/tweeters
focal 165ca1 coaxials
(2) image dynamics 10" IDQ10V3 drivers
custom enclosure
hertz ep4x 4 channel amp (150W x 4)
alpine mrp-mr1000 monoblock amp (500 x 2)
dynamatted interior
neoprene sound deadener
(2) 60mm volt gauges prosport evo
3-way usb hub molded in custom dash
key/lockable led valet switch for pc power in custom dash
more on this here...

- last updated: 4/30/2013


I'll try to update this weekly as progress is made!

Old Motor, it's had some abuse (265,000km...it did damn well over the years, though):

Attachment 334651

Pictures of the new motor and transmission:

4G69:

Attachment 334652

her new home for the next little while:

Attachment 334653

mix of used and new parts going in:

Attachment 334654

shiny new alternator:

Attachment 334655

dash pulled out, wiring the new harness into the cabin, new ECU hooked up and plugged in

Attachment 334656

manual shift cables bolted into place and fed into cabin:

Attachment 334657

old wiring harness disconnected, new one has since been mounted / hooked up to the ECU:

Attachment 334658

4G69 again:

Attachment 334647

ACT stage 3 and crazy clutch disc:

Attachment 334648
Attachment 334649

Intermediary shaft parts (5 pieces):

Attachment 334650

EVO VIII steering wheel, picked up off ebay for $200, airbag included too!

carbon fiber is an overlay piece from RexSpeed

Attachment 334646

Looks like a lot of fun. You will have a very unique Car once finished. Can you out an EVO8 front bumper on on of those? It would be sweet to turbo the 2.4 and have a FWD beast.

Yes you can its just really much wider than the rest of the car. Fenders and bumper..

I didnt think about the fender width since it is the front but it does meet on the sides by the flares.

I was thinking of putting on the EVO VII conversion kit by accolade, i think ratsbud is right though, the EVO body is quite a bit wider so you'd need to some fairly extensive body work to make it fit seamlessly - i could be wrong though, has anyone else successfully done this??

http://body-kit.com/lan02e7ts05.jpg

http://body-kit.com/lan02e7ts01.jpg

I do plan to turbo in the future, I'll be talking to Cranswick on that

looks awesome man, that stage 3 clutch is going to be insane, that unsprung disc is going to take some getting used to.

i've always liked that vii conversion...i was going to do it to my 03 ES, but i got a stock OZ rally kit in the same color for like $160 both entire bumpers plus lips, and skirts...that deal threw the vii conversion out the window, plus i decided the RA would be my fun car, and i would leave her body original.

any time you need some insight, i own both body styles, and both 4g94 and 4g69, not that you need to know anything about the 4G94 anymore :p

Looks good! Im totally in this for the Auto to Manual swap information. I have an auto RA and I'd love to make it manual some day.

Good work so far though! Keep it up!

thank you, once the new flywheel arrives (this week hopefully), i should have the motor and tranny in the car! i'm a bit intimidated by the clutch but i'll get used to it eventually - city driving is going to be a nightmare though - I'm hoping i don't regret getting the 4-pad unsprung disc.

im sure at this point i'll be going with the VII conversion from accolade (unlike other VII conversion kits, theirs doesn't require modifying the crash bar); i've budgeted for a new paint job (or 3M 1080 wrap); haven't yet decided on the color

i'll post some pictures this week and describe some of the areas we had to modify to switch from auto to manual. the same rules should apply in your situation; overall it's not that difficult but you'll need someone with metal fabrication skills to properly mount the clutch pedal assembly - that was the toughest part. you will need to cut an accurate circle through the firewall.

Nice build thread so far man. I'll be interested to watch this progress .

Thanks dude. Impressive work on your OZ turbo; wow 222whp!?

How are the Tein Coilovers btw? I was thinking of throwing those on soon actually (haven't bought them yet though)

Are 18's too big for the OZ; is that why you went with 17"; do they rub at all?

Cool build, can't wait to see vids of this thing :)

On another note, I'd stay away from the stock RA CMC, use one from a base Lancer or an Evo (read somewhere they were the same) as the RA unit has a bad habit of leaking when used with aftermarket clutches. Although it didn't affect everyone (Crans, it's your cue, lol), it seems to be a recurring problem.

Last thing, this thread needs more pics!

Thanks man its been alot of testing and tuning to get it to that but its well worth it :D. I can beat my buddy with his RB25DET swap in his 240 and another buddy with his Evo X english Tuned I could beat him from a roll on the highway. That is before he swapped over to all ETS hardpiping and 4" ETS FMIC and had english retune. I think he's got me now lol.

Tein coilovers ROCK!! Tein suspension components in general are great, high quality and functionally superior to alot of others out there in my opinion. Before the coilovers I had Tein S-Tech lowering springs which were great too. My car had 18's on it when I bought it. I hated them personally, mainly because of the style they were butt ugly but also for my plans 18's were just not gonna work. I cant recall if the 18's rubbed I got rid of them the first chance I had. My 17's rub a little bit but thats mainly due to the offset of them and I have to be at full lock going backwards at an angle for it to rub. I actually want to drop down to 16's soon so I can drop the car a little bit more for better cornering at autox.