bonkas tired old Lancer EX - Engine Swap/Build Thread

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Long time since I had an update on this...

Gearbox is now mated to the engine, after finding out the Donor EX had a sigma gearbox and 1200 driveshaft and unknown diff, I was under the impression from the seller these were all stock... I found this out when mating the gearbox was too easy! New clutch disk to suite the 1600 box and all is happy again - I now have the clutch parts required to mate the sigma box up after a quick inspection and possibly rebuild as it is in unknown condition and the donor car was in very rough shape, Interesting they didnt modify the shifter or floor at all to make this gearbox fit as I thought that was required.. maybe on in the LA LB lancers?

First time fitting a flywheel, clutch, pressure plate etc so it took a few goes before having everything correct but it should all be torqued to spec. I did find after mounting the gearbox there are some bolts which are missing, this is strange as I used all the bolts I had kept from the 1600cc motor, I can only think there may have been exhaust mounts or something that bolted here so I will have these bolts they are just in a different hiding place.

some pics for thread:


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Big day today. Feels like ive got over a huge hurdle and reached a milestone.

Car up on hoist:


It now has a heart.... not beating yet.. Thanks @ToMitz for the cam pulley, looks really sweet actually, much better than the stock pressed steel thing.


Have new engine mounts, new gearbox mount, master cylinder has started leaking like a fountain for some reason as I have not touched it, will need a new one of those too...

Next up is to bolt up odds and ends like alternator, radiator, put interior back together and start building the manifold with the help of my dad.

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Thanks to @Geophy I have my radiator pretty much sorted, just have to remove hunks of metal left in there from the radiator guy, I have got some out by shaking it, hoping I can get the rest out without cutting it open... Grrr.


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Turns out I should have measured more thoroughly... The fan I picked is too think by about 10mm and will not clear the water pump and pulley on the front of the motor.

Hopefully I have a fan coming which is 15-20mm thinner which I should be able to modify to fit the same as the old so I don't have to muck around with modifying or making a new shroud.


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Bit more progress today.

Got some misc parts cleaned up and painted.

Started building and mocking up the intake manifold, all looks good until mocked up against the engine.. Someone has put a damn Distributor in the way! also the carbs are very wide and ports on head are very narrow and close together. I think I will need to shave off the linkage and bosy of one of the carbs to make enough clearance to squeeze a throttle linkage in and clear the distributor cap. Sorry I have no pics of this.



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Dad slaved away all day yesterday for me.. I now have this:


Gotta weld in ports for vacuum lines, fabricate thermostat and heater piping next... Slowly coming together. 

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Today was a big win!

Intake is FINISHED!, machined some material out to space out the distributor the correct distance same as stock manifold.

Got Alternator mounted, had to modify the bracket as it was too close to the coolant hose and wouldn't let a hose clamp slip on. This is because I am using an alternator from a new model and had to make spacers to allow it to fit and machined the old pulley to fit the new alternator, because of this it sits in slightly different spot to the old one.

Got the Radiator and fan mounted for the last time, installed the bottom hose, top hose I will need to modify to allow the inline temperate sensor adapter - This will control my radiator fan.

Installed the temp sender for the dash gauge into the manifold under the thermostat, I have read this isn't really the best place for it but unfortunately there was no room anywhere else.

Got the heater hoses all plumbed up using various heater hoses from mitsi vans, commodores and falcons.

The Fuel pump is mounted... But I will need to replace this with another unit as the hose fittings don't have any barbs on the end and I am afraid I might get a hose pop off.

Finished the throttle linkages, just need a bit of adjustment and mount the bracket that hold the cable somewhere.



Next on the list:

  • Find another low pressure pump
  • Mount Fuel Regulator
  • Find some air filters that will let me use the air trumpets
  • Mount fuse box
  • Mount vacuum pump
  • Wire up Fuel Pump, Radiator and Vacuum Pump
  • Install distributor, plugs and leads for the final time

If anyone can help with the above especially the fuel pump, find a quiet vacuum pump and if your in the Waikato and can offer a hand with the wiring!

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Despite a massive water leak from the pipe that runs into the back of the water pump... The O-Ring seal it came with from factory appears to be too small.

But I succeeded in this:


Bit of carb tuning and watching oil pressure and she idles sweet as. The oil pressure gauge in the dash is really jumpy and inaccurate but I have confirmed with an external oil pressure gauge I am getting 60PSI of pressure so I am ignoring that for now.


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Tad bit longer video with a bit of a rev up after getting alternator working.

Alternator is pumping out a massive 15v so will probably cook this battery is short order, anyone have hookups on calcium batteries? It is my thinking they require higher charge voltage and might be a good fit, otherwise auto electrician said he may be able to bring voltage down.


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