Stripping the interior

 

wiring harness off a 240sx and stock harness clean up.

Complete 240sx Intake... First thing I did was remove the secondary butterfly's.

 

First thing is to take off the plates in each runner, each are held in by 2 screws. Then take off the SVC control valve and slide the rod that holds the plates out.
 

Next thing is to either get a plate to cover the hole in the back of the intake (where the SVC valve goes) or weld it shut.
I had my friend weld it.

 

Holes for SVC rod thru the runners welded shut (no necessary)

Removing the coolant hardline from the upper intake plenum.
I had to grind all the material off to make if flush. There is a cavity behind it which will need to be welded shut.

Some cleaning and it's ready for welding.

Took the upper plunum to get the hole welded shut. Throttlebody assy cleaned up.

 

Some misc parts chrome plated.... throttle brackets and a heater hose plate.

Complete intake.

Powder coated parts (Candy Red).
 

Finally found the truck KA24E motor.

 

Old Z24 comes out.

 

KA motor and intake.
 

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KA in truck (6/14/2006).....(7/19/2006-07/20/2006)

The KA motor brackets do not line up with the 720 frame brackets and the angle is also different. I have to remove the brackets from the frame. I got the 240sx motor mounts (in the pic) and tested them once the motor was leveled and centered.

 

My plan was to use the 240sx Cross member and cutting off motor mounts brackets and welding to the 720 Frame. But after testing the 240sx motor mounts (left on second pic) I found the frame doesn't provide enough clearance to put the nut on the bottom stud on the mount. The KA (middle) and Z24 (right) mounts have a plate that bolts to the frame brackets but have different lengths.
 

Stock Z24 Frame mounts removed. I have the hardbody frame brackets, but they didn't fit well on the 720 frame so I decided to reuse the Z24 frame brackets and relocate them to work with the KA. I also made the Z24 motor mounts work on the KA motor brackets by drilling a hole for the guide pin.
 

The difference between the Z24 (right) mounts and the KA truck mounts (left). The guide pin right above the monting stud on the Z24 mounts is offset to the side and the KA mounts have the pin right above the mounting stud. Also the lenght of of the plate that mounts to the frame.... the KA mounts are longer and are offset to one side (both sides are the same). The Z24 has a shorter plate and is centered. To make the Z24 mounts work on the KA brackets I drilled holes on the brackets.

Stock Frame brackets relocated and ready to weld.

Intake upper plenum polished.

 

Ok back to work on the swap... firewall is finally painted.

Motor back in.

Aug 17, 2007

Underdrive pulley

Aug 20, 2007... Intake on motor (Finally).

Sept 20, 2007... Fenders and lights.

Sept 22, 2007.... Sorting out wiring.

October 15, 2007.... Lower Intake Plenum polished.

 

 

December 09, 2007 ..... Valve cover finished.

 

 

Ceramic coated headers. After some cleaning up and polishing

 

Test fitting headers. Powder coated pulley

 

 

Walbro fuel pump installation (03/24/2008).

 

 

Intake and tubing

 

 

Intake tubes cut and modified. (04/05/08)

 

Koyo Aluminum Radiator. (04/05/08)

 

Finally up and running. August 2008 

 

  

 

Alot of question have been asked about the wiring. To clarify.

I used the 240sx harness plugs and 2 relays (Fuel and Main ECU power) and spliced that into the 720 harness.

I placed the 2 relays in the passanger side (factory bracket holds them perfect).

 

Factory harness plugs were also removed from 240sx fusebox. In the second pic you see the engine harness has the Blue ECU plug. There is only 3 plugs you have to worry about (brown, gray and the white one in the second pic).

Here's some pics I found that will be very usefull for most of you.

This long brown plug is the same as the long white plug on mine. The orange needs to go to the starter signal wire. The Temp and tach are on this plug too. I was able to wire my Autometer tach by simply tapping into the wire (no adapter needed).

 

This is a 510 Diagram for SR20 but it applies to the KA as well.

 

Index
1. General info
2. Performance Upgrade
3. Interior & Sound
4. Exterior & Paint
5. Suspension Upgrades
6. Fiberglass Projects
7. KA24E Engine Swap 
8. Firewall changes (room for Turbo)
9.  Turbo
10. Misc pics (Quads and Truck)