Outlander I CU2W 4G63 DOHC swap to SOHC 4G63
Purchased this Outlander I with broken timing belt
As the main belt is broken decided not to rebuild DOHC 4G63 engine but to replace it with SOHC 4G63 that is came of Mitsubishi GALANT SALOON VIII EA_1996–2006.
As it was stored for other project.
As for start inspected SOHC engines condition.
Purchased new belts pulleys what looked needed changing.
Once planed inserting it to CU2W needed to think something about engine mounts alternator and other things that don't look similar to do bolt on swap.
So first problem was main timing side engine mount, that is different on both engines. Had to grind bit of aluminum cast mount part to fit if on 4g63SOHC engine.
Once mount is redone to fit GALANT SALOON VIII EA_ 4G63 SOHC engine checking other belt drive parts as sohc has 4PK belt compared doch has 6pk belt drive so need to change pulley on generator.
after that needed to change all the heat shield holders and exhaust manifold holders on 4g63block. Also needed to change the wlywheel as it's different on Outlander I CU2W 4G63 DOHC compared to GALANT SALOON VIII EA 4g63 SOHC. Also needed to swap center diff cool/heat feed line from block as soch does not have it. For same center differential cooling/heating line needed to add three-pronged hub for diff as soch does not have that on water pump pipes.
After all that work around engines back and front of block got in situation that need to swap throttle body of Outlander I CU2W 4G63 DOHC to GALANT SALOON VIII EA 4g63 SOHC as wiring will not work. Just bolted on the TB without any modifications.
once all works around engine is done inserted engine to Outlander I CU2W
As i did not cut any wires or plugs wanted to keep all OEM thing there needed to make extended wire for Crankshaft position sensor.
Problem with swap is Oil pan, that is in different shape then Outlander I CU2W 4G63 DOHC compared to GALANT SALOON VIII EA 4g63 SOHC, o left it as it is as i will be placing DOHC engine back.
As i the swap was done to use most bolt on techniques the things what was modified is: Timing side engine mount - grinded.
