So I have performed an engine swap on my 91 Lancer using a G4CP out of a 1994 Hyundai Sonata automatic.
It started out as I needed to replace my water pump because someone used the wrong one but when you see a Sonata for sale that has the engine you want with only 109k km for $350 you decide to do the swap.
So first I pulled out the G4CP and then scrapped the Sonata roller.
Since I had a timing kit for the 4G61 I used everything but the belt on the 2.0 and bought a new balance shaft belt and timing belt. I also bought a AEM uego kit (so I can keep the fuelling in check), new hose clamps, new belts 4pk990 and whatever it is for the power steering pump (same for the 1.6 and 2.0), new fuel filter, new clutch kit, 2 bottles of oil (1 5L 10w40 shell helix for the first 500km and a 6L bottle of penrite 15w40 for an oil change for after the first 500km), 2 oil filters, bottle of penrite power steering fluid, 1 bottle of penrite dot 4 brake fluid (for the clutch) and probably a couple other small bits I've forgotten at this time.
So first I started on the 2.0.
I did the timing belt, seals and swapped over the rocker covers (I prefer my original 1.6 one). I left the sonata engine mount points on (the ones that sit behind the timing belt) as they are the same as the 1.6. I then put the lancer mounts that bolt to the block on the 2.0 (lancer ones must be used as they are completely different to the sonata).
I put my 1.6 intake on the 2.0 (bigger runners and huge ports unfortunately restricted by 2.0 head), swapped the throttle bodies (sonata has a bigger one), bolted on the lancer exhaust manifold (has smaller outlet ports but I didn't grab the sonata down pipe so I couldn't use the sonata manifold (I plan on extractors very soon anyway), I left the 2.0 alternator on as well as the water pipe (the water pipe is different between the 2 but I used a upper rad hose for a 92-94 Toyota Tarago and it fits perfectly), 1.6 thermostat housing, the Lancers cas must be used (2g compared to sonata 1g), I'm using the 2.0 240cc injectors and fpr (unknown pressure) instead of the 1.6 210cc injectors and 270 kpa fpr to compensate for the bigger engine and then I'll swap things out as necessary to give better fuelling.
I had the flywheel machined and I cleaned everything up and then fitted the flywheel, clutch and gearbox.
The connecting bar that goes from the gearbox to intake manifold can not be used due to extra deck height but if modified it can obviously be used.
Next it was time for fitment.
I started putting the engine in and it all dropped into place as it should. I bolted up the engine mounts and then plugged in all the connectors and hooked up the lines, the exhaust was connected up, airbox and battery tray in and those too were connected.
I filled up the engine oil and radiator, turned the key a few times to prime the lines and then turned it over. After a few second it started and ran perfectly. I shut it off and here I am now typing this.
All that's left to do now is put the driveshafts back in, connect the brakes, put the hood on, pull out the cat and knock the guts out, weld in my o2 bung for the wideband, fix an exhaust leak, top up the gearbox, bleed the clutch, put my steering wheel on (bought a boss kit for it but its the wrong one and I may need a evo 1),
It started out as I needed to replace my water pump because someone used the wrong one but when you see a Sonata for sale that has the engine you want with only 109k km for $350 you decide to do the swap.
So first I pulled out the G4CP and then scrapped the Sonata roller.
Since I had a timing kit for the 4G61 I used everything but the belt on the 2.0 and bought a new balance shaft belt and timing belt. I also bought a AEM uego kit (so I can keep the fuelling in check), new hose clamps, new belts 4pk990 and whatever it is for the power steering pump (same for the 1.6 and 2.0), new fuel filter, new clutch kit, 2 bottles of oil (1 5L 10w40 shell helix for the first 500km and a 6L bottle of penrite 15w40 for an oil change for after the first 500km), 2 oil filters, bottle of penrite power steering fluid, 1 bottle of penrite dot 4 brake fluid (for the clutch) and probably a couple other small bits I've forgotten at this time.
So first I started on the 2.0.
I did the timing belt, seals and swapped over the rocker covers (I prefer my original 1.6 one). I left the sonata engine mount points on (the ones that sit behind the timing belt) as they are the same as the 1.6. I then put the lancer mounts that bolt to the block on the 2.0 (lancer ones must be used as they are completely different to the sonata).
I put my 1.6 intake on the 2.0 (bigger runners and huge ports unfortunately restricted by 2.0 head), swapped the throttle bodies (sonata has a bigger one), bolted on the lancer exhaust manifold (has smaller outlet ports but I didn't grab the sonata down pipe so I couldn't use the sonata manifold (I plan on extractors very soon anyway), I left the 2.0 alternator on as well as the water pipe (the water pipe is different between the 2 but I used a upper rad hose for a 92-94 Toyota Tarago and it fits perfectly), 1.6 thermostat housing, the Lancers cas must be used (2g compared to sonata 1g), I'm using the 2.0 240cc injectors and fpr (unknown pressure) instead of the 1.6 210cc injectors and 270 kpa fpr to compensate for the bigger engine and then I'll swap things out as necessary to give better fuelling.
I had the flywheel machined and I cleaned everything up and then fitted the flywheel, clutch and gearbox.
The connecting bar that goes from the gearbox to intake manifold can not be used due to extra deck height but if modified it can obviously be used.
Next it was time for fitment.
I started putting the engine in and it all dropped into place as it should. I bolted up the engine mounts and then plugged in all the connectors and hooked up the lines, the exhaust was connected up, airbox and battery tray in and those too were connected.
I filled up the engine oil and radiator, turned the key a few times to prime the lines and then turned it over. After a few second it started and ran perfectly. I shut it off and here I am now typing this.
All that's left to do now is put the driveshafts back in, connect the brakes, put the hood on, pull out the cat and knock the guts out, weld in my o2 bung for the wideband, fix an exhaust leak, top up the gearbox, bleed the clutch, put my steering wheel on (bought a boss kit for it but its the wrong one and I may need a evo 1),