So, you’re looking to boost the power of your Mitsubishi Lancer? Swapping in a 4G64 engine is a popular and effective way to significantly increase horsepower and torque. This guide, tailored for the DIY mechanic, will walk you through the essentials of performing a 4g64 Obd2 engine swap, drawing from successful community experiences to help you navigate this upgrade.
Essential Parts for Your 4G64 OBD2 Swap
This swap isn’t just about dropping in a new engine; it requires careful component selection and integration to ensure compatibility, especially with your Lancer’s OBD2 system. Here’s a breakdown of the parts you’ll need:
Engine and ECU
- 4G64 Engine (2000-2005 Mitsubishi Eclipse/Galant): The heart of your upgrade. Opt for a 2002+ 4G64 to simplify camshaft reluctor compatibility.
- Mitsubishi Lancer Evolution 8 ECU: Crucial for managing the 4G64 and ensuring OBD2 compliance. Part number MN132874 (with 94170015 file flashed) is a known compatible option.
- OBD2 Tactrix Cable 1.3u: Essential for ECU hacking. This allows you to disable the immobilizer and tune the ECU, ensuring proper communication with your Lancer’s OBD2 system. Limitless.co.nz is a recommended source.
- Intake Manifold: The stock 4G64 intake manifold works, but consider an aluminum Outlander manifold for increased durability, addressing common cracking issues in the stock Eclipse manifold.
- Exhaust Manifold: Stock 4G64 manifolds are compatible with 4G63T flange patterns, meaning Evo 8 or 2G Eclipse exhaust manifolds are bolt-on options.
- Injectors: Stock 4G64 injectors are sufficient for this swap.
- Alternator, Power Steering Pump, A/C Compressor: Retain the stock 4G64 units with their respective brackets. The A/C compressor from your 4G94/4G64 will also fit, ensuring continued functionality of your car’s air conditioning system.
- MAF Sensor: Use a 501 Eclipse MAF sensor for proper air flow measurement.
- Motor Mount: The engine-attached mount from the Eclipse 4G64 is necessary, requiring custom brackets for Lancer chassis mounting.
- Radiator Hoses: Utilize a stock Eclipse lower radiator hose (trimmed by 1 inch on each end) and a stock Lancer upper radiator hose for cooling system connections.
- Heater Hose: Approximately 14 inches of 5/8 heater hose will be needed for heater core connections.
- Coil Packs & Plug Wires: Your factory Lancer coil packs are compatible, although one spark plug wire may be slightly short.
- Valve Cover & Oil Pan Gaskets: Replacement gaskets are advisable to prevent leaks, as often these components on donor engines can be aged or damaged.
Transmission and Drivetrain
- K5M422F6ND Transmission (2000-2005 Eclipse 5-speed): This transmission is a direct fit and robust enough to handle the 4G64’s increased power.
- Top Tranny Mount (Left Motor Mount): Source this from a 2000-2005 Eclipse for proper transmission mounting in the Lancer chassis.
- Slave Cylinder: Ensure you obtain the banjo bolt and fitting along with the slave cylinder.
- Lancer Differential: Swap your stock Lancer differential into the Eclipse transmission. The Eclipse transmission has larger axle inputs, incompatible with stock Lancer axles without this differential swap.
- Lancer Drive Shafts: After swapping the differential, your stock Lancer drive shafts will be compatible.
- Eclipse Starter: The Eclipse starter is required for proper fitment with the 4G64 engine and K5M422F6ND transmission.
Wiring and Sensors for OBD2 Integration
- Stock Lancer Wiring Harness: Reuse your existing Lancer wiring harness to simplify integration.
- Sensor Clips (Crank Angle, Throttle Position, Power Steering Pressure): Obtain 4-inch pigtails with clips for these sensors from an Eclipse or compatible Mitsubishi model. These are needed for adapting the Lancer harness to the 4G64 sensors and ensuring correct OBD2 readings.
Miscellaneous Essentials
- Fluids and Filters: 5 quarts of your preferred engine oil and a new oil filter, 3 quarts of gear oil, power steering fluid, and brake fluid for clutch bleeding.
- NGK Spark Plugs: 4 NGK spark plugs recommended for optimal performance.
- Mitsubishi CAP M/T (MD746157): Order this cap from Mitsubishi for sealing when disassembling the transmission for differential swap.
- Slim Radiator Fans: Consider 1 or 2 10-inch slim radiator fans. Relocating fans to the front of the condenser may be necessary for clearance and improved cooling.
Addressing Common CELs and OBD2 Issues
After the swap, you might encounter a few common Check Engine Lights (CELs). Here’s how to troubleshoot them, keeping your OBD2 system happy:
- P0123 (TPS High Input): This typically indicates incorrect wiring to the Throttle Position Sensor. Double-check your TPS wiring against a 4G64 wiring diagram to ensure correct connections.
- P0113 (IAT High Input) & P0107 (MAP Circuit): These codes, related to the Intake Air Temperature sensor and Manifold Absolute Pressure sensor, often arise from wiring discrepancies or sensor incompatibility. Verify sensor compatibility and wiring.
- P0455 (Evap Control System): This EVAP system code can appear if emissions plugs are not extended properly during the swap. Rerouting or extending these lines may be necessary. Running a new code in periphry2 might also resolve this without physical modifications in some cases.
Utilizing your Tactrix cable and Evoscan (or similar OBD2 software), you can diagnose and clear these codes, ensuring your 4G64 OBD2 setup is running smoothly and efficiently.
Performance Notes and Considerations
- Cooling: Initial reports suggest slightly higher coolant temperatures compared to the stock 4G94, even with dual fans. Consider a lower temperature thermostat and/or a thicker core radiator for optimized cooling, especially in warmer climates or during demanding driving conditions. Monitoring coolant temperatures via OBD2 data logging is recommended to ensure safe operating conditions.
- Fuel Economy: Expect a slight decrease in MPG compared to the 4G94. Real-world data indicates a drop from around 33 MPG to 28 MPG with stock intake and exhaust systems.
- OBD2 Tuning: The Evo 8 ECU opens up significant tuning potential via OBD2. Custom tuning can optimize performance, fuel economy, and address any sensor or fueling adjustments needed for your specific setup.
Conclusion: Unleash Your Lancer’s Potential with a 4G64 OBD2 Swap
The 4G64 OBD2 engine swap is a fantastic upgrade for Mitsubishi Lancer owners seeking substantial power gains. While it requires careful planning, parts sourcing, and diligent execution, the result is a significantly more powerful and responsive vehicle. By following this guide and leveraging OBD2 diagnostics for tuning and troubleshooting, you can successfully transform your Lancer into a true performance machine. Remember to consult online communities and resources for further support and detailed wiring diagrams to ensure a successful swap.
