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    Thread: My turbo charged Mitsubishi Lancer Diesel

    1. #1

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      My turbo charged Mitsubishi Lancer Diesel

      Flashback,

      My first encounter with Mitsubishi Lancer happened during 2008 when I decided to upgrade to a pocket friendly sedan which is reliable, fun to drive, can accommodate 5 passengers and their belongings with comfort.

      With the limited budget of 4 to 5 lakhs I hit the car market looking for used sedans. To beat the high depreciation cost of a new car and the low to moderate kilometers usage, I’ve decided to stick to pre-owned car rather than going for new one.

      First I came across a low mileage Hyundai Accent DRDI single owner car. I was inclined towards the car since the car looks good both inside & outside and the asking price was within my reach. Almost decided to settle the payment, but then at the last minute pulled back after came to know the car’s windshield was replaced recently and some paint work was done at the front.

      I’m a resident of Adyar, with Maya motors (ASS for Mitsubishi motor) in close vicinity, have seen so many lancers, Pajeros & Montero Kris crossing the roads every day. So the brand Mitsubishi started to grow stronger inside me. Promised myself to get one Mitsubishi car one day for sure.

      A friend of mine showed me a pre-worshiped Mitsubishi Lancer diesel, a 2004 GLXD model with 65K in the ado in pristine condition. Without looking further settle the amount and got hold of the baby. Immediately on taking possession, upgraded the tires to 205/55/R15 Yokohama S-drive with HR alloys and switched to 2 Din JVC with pioneer speakers.

      Here are few of the shots from my archive,

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      Now my long journeys in Lancer became very comfortable because,

      1. It has large boot
      2. seating comfort & leg room space
      3. Its valet friendly too, thanks to the diesel motor under the hood

      With every passing journey, I’m quite additicted to Lancer’s driving dynamics. Properly weighed steering that allows one to place the car exactly in the position one want it to be and the mannerism with which it takes on twist and turn is simply amazing.

      Carried out the following mechanical upgrades moment it hit the 90k kilometer mark,


      1. Timing/alternator/radiator belts
      2. Front/rear shock absorbers
      3. Engine bed
      4. Engine/radiator flushed using OWS products.


      Its year 2011, Lancer has crossed 1, 15, 000 KMs, it has started showing its age. There is a perception in my mind that the highway ride is taking too long to cover. The diesel Lancer available in India puts out 68 BHP which is too low in 2011-12 standards, so started exploring the options of giving her more horses. To my disappointment every one I’ve contacted, suggest that it’s very difficult to carry out any sort of modifications to diesel lancer.

      Reason:

      1. lancer diesel sold is India is old school/manual mill not ECU driven like its petrol counterpart.
      2. Fuel injection system is not common rail; it’s an electronic pump type.

      Heard lot of horror stories in an attempt to turbo charge the laner diesel engine, so dropped the idea of adding a turbo altogether.

      While casually surfing the net, came across the information that the same Indian model diesel engine is available in various state of tunes in rest of the world. The engine code is 4D68T. It’s the same engine that is powering the Indian lancer, the only inclusion being turbo charged from the factory. The turbo charged non-intercooler puts out 80PS, whereas turbo charged intercooler from the factory puts out 90PS.

      Started day dreaming about sourcing this 4D68T engine and swap that into my lancer. Months passed without making much progress due to the fact that there is very little or no information available at lot about this engine swaps in the Indian context. Reached out to as much people I know, but there is no reliable info on the price/possibility of getting one to India.

      At last one gentle man shown such engine claiming it’s a 4D68T engine and its fits the lancer. Was disappointed after seeing the condition of the engine, it’s a complete crap, not even sure whether it’ll run or not. Also the mechanic not sure about the kind of modification to be done to fit that engine. Moreover everyone I talked to, discouraged me not to pursue this swap, citing reason like long term reliability and availability of spare parts for such an engine.

      The dreaming of swapping a 4D68T engine came to a grinding halt, with heartbroken, sold the lancer in 2011 Q1.

    2. #2

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      September 2011, new ride joined my family; it’s again a pre-worshiped, Skoda Laura 1.9 PD 2010 model which has clocked 16k in the ado.


      Though I’ve a much better sedan in hand in the form of Laura than the old school Lancer, that abandoned Lancer turbo project itched somewhere deep inside my head and refuses to die down, thanks to other similar project that are doing the round in the social networking forum (e.g Amey's Lancer project)

      Again years passed by and in Jan 2014, got a credible source of information about a person whom I can rely on in souring the same 4D68T engine.
      In the same week got a chance to talk to the person and the outcome of the conversion was very encouraging. He was willing to source one for me and also learnt the engine 4D68T is a straight bold on, no modifications what so ever needed to fit that engine into Indian made Lancer diesel chassis. One little disappointment though, I was hunting for that 90 PS factory fitted inter-cooler model, but the person willing to source only the non-intercooled model. Paid the advance for the non-intercooler model thinking I can anyway add an aftermarket inter-cooler and thereby take the power out to match factory fitted 90 PS model.

      From approximately 20 to 30 days from the data of advance payment, the engine has landed, without wasting no time relocated the engine to my reliable garage from where the whole transplant going to be carried out. One happy soul at last.

      Here is few of the snaps while the engine lying in the garage floor,

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      Below is the Galant powered turbo charged inter-cooled from the factory,

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      Last edited by Kaithu; 23rd Nov 2015 at 21:12.

    3. #3

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      Having secured the turbo charged diesel engine, the next set of action is to tracked down a well maintained donor lancer and that too a diesel, otherwise engine mounting needs to be fabricated which I don’t want to do. I’ve waited, waited and almost waited for 3 months, finally settling on a LE model which was as original as possible. Everything in working condition from power windows, electric OVRMs, cassette player , antennae, fog lamp etc...

      Here is couple of shots of the donor car. Yes I agree the paint scheme in the car is uninspiring and boring. It would be better if it’s a black or yellow or red in color.
      If one looks beyond the color, the car is as straight and original as possible.

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      Now both the donor car and the engine was with me, started planning the dates to complete the engine transplant. The plan is to complete the swap in 5 – 6 days since it’s a straight bolt on swap, no modifications whatsoever was needed to carry out the swap. Since the time available is short, ordered the below essential spare parts in advance.

      1. engine flush
      2. engine oil
      3. oil filter/fuel filter/air filter
      4. two engine mounts & two gear box mounts
      5. timing belt/AC belt/alternator belt/ fan belt
      6. brake pads
      7. KYB shock absorbers and struts mounting kit
      8. Channel rubber (the one in the car has perished)

      Started the swap on one fine Monday morning. First the non turbo engine in the car was dropped. Then all the wiring harness and radiator hoses are swapped between the engines.
      The auto gear box from the turbo engine was removed and the manual gear box from the non turbo engine was matted with the turbo engine.

      The A/C compressor in the donor car is of clutch type and the one that came with the turbo engine is of piston type. Seems the clutch type compressor puts lot a strain in the engine when compared to the piston type. So swapped the piston type A/C compressor as well.

      As planned the swap was completed by Friday and took delivery of the car on next day evening itself. This is an as simple swap as possible. I’ve reused the same manual gear box, same engine wiring, same radiator plumbing, same fuel line and even no change to the exhaust system, not even the exhaust manifold where the turbo sits.


      This is the final outcome of the build,

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    4. #4

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      Let me try to answer some of the questions about this transplant attempt,

      Is this build an easy and straight forward?
      Yes this swap is as easy and simple as possible, since no changes are needed to the engine mounts.

      Is this build reliable?
      Yes it is utterly reliable as its stock engine in the international market sometimes back. Have driven close to 16,000Kms after the transplant, no issues whatsoever I’ve faced till date. No erratic engine temperature, no oil or radiator coolant leak. Power delivery is very linear.

      Is this build expensive?
      No. This is as cheap build as possible as far as I know.

      Is this build completely transforming the power output of the car?
      The answer is part Yes and part NO. Now with this turbo engine, the car pulls effortlessly from lower gear and it can quickly reach 3 digits figure with ease when compared to the non-turbo engine. But what is lagging is the engine refinement level when compared to today’s modern common rail counterpart and its easily running out of breath due to small sized turbo. Overall I’m quite happy with the outcome of this build.

      Will I recommend this to someone who owns a lancer diesel and want to improve its performance?
      Yes TC engine definitely makes a difference. For someone who loves his lancer and don’t want to give it up, this is a welcome change.


      What’s next?

      Car put under a dyno test and following is the output,


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      Seems there is carbon buildup in the engine and decarbonizing the engine might take the numbers close to 85BHP.

      Questions: I'm thinking of the following to safely push the numbers close to 100 BHP

      1. decarbonize the engine
      2. K&N apollo filters
      3. larger diameter turbo down pipe
      4. separate breather pipe
      5. EGR valve blocking
      6. If I understood correctly, a properly fitted inter-cooler (front mount/top mount) might increase the output by 5-10%.
      7. good after market turbo charger like garret may even push the out to higher levels. This is in theory; I’m not sure whether the same can be released in this old school engine.
      8. Is it feasible to install a VGT in a non ECU based diesel engine thro' a standalone ECU module which takes care of VGT part?

      Any other suggestions to improve the power band across the spectrum?

      One of my friend who did the same transplant went ahead with the intercooler install (top mount) and happy with the outcome,


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      Also i'm thinking of this minor cosmetic changes to lift the car’s appeal a bit,

      1.black roof vinyl wrap
      2.evo 9 rear spoiler/ front grill.

      Hope the information shared in this post will be helpful to others in one form or the other especially to fellow lancer owners.

      Looking forward to your valuable suggestions/comments to take the build to next level.
      Last edited by Kaithu; 24th Nov 2015 at 12:57.

    5. #5

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      Looking for your opinion/comments on the following changes and will it really make a difference in terms of performance in real world road conditions,

      1. engine decarbonization
      2. replace stock with K&N apollo filters
      3. turbo down pipe upgrade
      4. separate breather pipe
      5. EGR valve blocking
      6. top mount inter-cooler (pajero type)

      Also i would like to know the possibility of replacing the existing "fixed geometry turbo" with "variable geometry turbo".

      What i know is the vanes in the variable geometry turbo's are controlled by ECU based on various parameters of the engine. So it will be a uphill task to switch to VGT from FGT.

      But still want to hear from you guys on the remotest possibility of fixing VGT in a non ECU based diesel engine like lancer.

      Or any other after market turbo setup i can relay on to push the performance figures up further.

      Thanks in advance.

    6. #6
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      1. Use Xado Anti Carbon -

      http://xado.co.in/product_details.php?product_id=51 for your cylinders

      and http://xado.co.in/product_details.php?product_id=83 in your oil

      Brilliant results from personal experience. I have used in in my car with outstanding results. I had put up pics of it somewhere.

      2. K&N and such - stay away! More trouble than they are worth. Stick with stock paper filters.

      3.& 4 - will not help at all in your current setup. Waste of money on a sub 100hp engine.

      5. EGR blocking - will help ONLY with an appropriate tune - else your fuelling will go for a toss.

      6. If buying anything other than an OE intercooler, then it'll have to accompanied by an appropriate remap. Else you will see a big drop in boost (and performance).

      7. Nothing will boost power as much as a remap will. However that depends on whether your car has an ECU and is removable at all. If yours is a non common rail system, the gains may not be as much.

      The engine tech is ancient - hence not too many of us will have much information on it. Looks at forums abroad to see what the possibilities are with this engine.
      A closed mouth gathers no feet.

    7. #7

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      Aman Bungay's Avatar
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      Nice swap,
      Between what are the new fuel efficiency figures? Increased or decreased than the stock engine?
      I also have a lancer(petrol).

    8. #8

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      Quote Originally Posted by Aman Bungay View Post
      Nice swap,
      Thanks

      Quote Originally Posted by Aman Bungay View Post
      Between what are the new fuel efficiency figures? Increased or decreased than the stock engine?
      After the swap, I'm getting 15 to 16 Kmpl consistently in the highways with AC ON all the time with speed between 90 - 110. In the city's bumper to bumper traffic FE stands around 9 - 10Kmpl. I think stock will be giving some 2-3 Kmpl more than the TC engine.
      Last edited by Kaithu; 25th Nov 2015 at 13:16.

    9. #9

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      Quote Originally Posted by kb100 View Post
      1. Use Xado Anti Carbon -

      http://xado.co.in/product_details.php?product_id=51 for your cylinders

      and http://xado.co.in/product_details.php?product_id=83 in your oil

      Brilliant results from personal experience. I have used in in my car with outstanding results. I had put up pics of it somewhere.
      Thanks for your suggestion, Will give it a try.


      Quote Originally Posted by kb100 View Post
      If buying anything other than an OE intercooler, then it'll have to accompanied by an appropriate remap. Else you will see a big drop in boost (and performance).
      Yes i'll stick to an OEM intercooler. The plan is to get one Pajero type top mount intercooler to beat the drop in boost.


      Quote Originally Posted by kb100 View Post
      The engine tech is ancient - hence not too many of us will have much information on it. Looks at forums abroad to see what the possibilities are with this engine.
      Since this engine is very old school and non ECU type, i think not much information is available in forums abroad either.

      If i understand correctly the presence of a factory fitted turbo in an engine gives the tuner more room for performance modification.

      So my stupid question is,

      1. Is it possible to upgrade to "variable geometry turbo" from "fixed geometry turbo"
      2. What about the possibility of a twin turbo setup like the one in Mahindra Quanto.

    10. #10
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      Quote Originally Posted by Kaithu View Post
      Yes i'll stick to an OEM intercooler. The plan is to get one Pajero type top mount intercooler to beat the drop in boost.
      No - this is not what I meant by an OEM intercooler. Get an intercooler that was originally used with this engine. If not get one that is of the same volume.

      An FMIC (Front Mounted Intercooler) is way more effective than a top mounted one - for a whole bunch of reasons. Go for a FMIC - you can get yourself a boost controller to compensate for pressure drops.

      Quote Originally Posted by Kaithu View Post
      If i understand correctly the presence of a factory fitted turbo in an engine gives the tuner more room for performance modification.
      Non ECU engines are the most difficult to tune. The advent of ECU made everything related to engine management so easy! The ECU can compensate for various variables (fuelling, ignition, timing etc etc etc)- whereas its impossible to do that in a car without it. VGT is entirely ruled out.

      Please, therefore, drop any plans of turbo upgrades etc with this engine - it'll be a thankless money pit. If you want better performance, the cheaper, and infinitely more reliable, option would be to get yourself a more capable modern engine.
      A closed mouth gathers no feet.

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