91 240sx KA-T build aka BoOzTd NiGhTmArE

[CHRISTIANELIO]

Back in January of 2009 I bought a red 91 240sx coupe 5spd for 800 bucks .With in a month or two i decided to turbo the stock KA24DE. So I had a couple thousand to do so .

Parts I ordered :

ebay t3/t4 turbo to4e

cx racing tubular manifold top mount cx racing intercooler kit designed for the s13 godspeed 38mm wastegate

oil filter sandwhich plate (for oil pressure gauge ,and oil feed )

oil feed line stainless line 3 1/2 ft long with fittings

small lawn and garden battery (stock battery wont fit since the battery tray has to be cut for the cold side of the intercooler piping .

walbro 255lph fuel pump

greddy type rs bov (cx racing kit came with rs flange out of the box )

ngk bkr6e spark plugs greddy profec 2 boost controller

greddy emanage blue ( just buy the cable from http://www.giff-tech.co.uk/ for 45 bucks and one week of time to get it instead of buying the real greddy one for over 100 dollars or wasting your time making one with a dku-5 nokia cable

5bolt flange for the turbo

custom down pipe since clearance is a issue with the brake master cylinder (bmc)

apexi cat back exhaust

ebay short throw shifter (really nice )

amico stage 3 clutch -6 puck stock flywheel

bayspeed full body kit

so after getting the turbo kit on and the car running good I added 550cc injectors and a wideband 02 sensor aem .

The car ran so good at 8 psi and sounded amazing with the greddy bov and the open atmosphere wastegate . I did run into several problems the manifold cracked where the wastegate bolted up . so instead of sending it back and getting the same one i had a shope weld and reinforce all the welds for durability . Works great !!!

Another problem was crankcase pressure .**I didnt block the pcv valve ,so under boost I was boosting the crankcase Opps!! removed !!

The entire ebay kit / turbo is a great buy for the money imo .

Well one day I decided to turn up the boost, so I uped it to 12 psi on the greddy ebc which is by far the coolest thing ever lol . after a couple weeks of 12 psi my car started smoking big time .

So I looked around for another motor and found one from a 96 s14 . swapped it in and could never get it to run . I got mad and spent hrs on it and found out it had no compression . (GAY) so i decided to sell it(4-2009 ) and get the following 93 honda cbr 600 sold 2 months later then got 97 mitsubishi eclipse gst 400hp +sold 11/2009 then got 97 s14 sr20det powa-sweet car sold 1/2010 after doing a stock rebuild 91 s13 hatch (stock for sale actually 1700 dollars )

So after about 10 months I sold my s14 and had money to buy another project car which i wanted to turbo .

Then one day I was looking in a local forum and found my old 91 coupe ka-t and bought it back just recently 1/2010 , YAY!!!!

Then guy I sold it to still didnt get it running . so first thing i checked was compression lol !!!! 1-35psi 2-3-4- 175psi well my problem is still the same from when I had the car .(what do ya know )

When i bought it back he included the following new 17in rims black polished lip 5 star new oil pressure gauge auto meter new boost gauge auto meter as well brand new 550cc injectors

So I got a hell of a deal !!! 2500 for all of it delivered to my house !

So since i sold my s14 I still had left over cash to finally do a correct engine build !

I purchased

wiesco pistons 9 to 1 compression .020 over with rings and all parts

eagle rods with arp 2000 bolts

full felpro gasket kit w/head gasket

clevite main bearing std size

clevite rod bearing std size

arp main studs for a l20 engine and added 3 longer studs to complete the kit since arp doesnt make a actual main stud kit for the ka motors

arp head studs for a saturn same bolt /thread size (same goes for the head studs arp doesnt make them for ka's (stupid I know )

Black 2in header wrap for my manifold and down pipe .

[CHRISTIANELIO]

new body kit turbo kit installed pulling old engine out getting ready to be built ! my head after the machine shop cleaned and checked the head . oil pump,oil filter housing water neck intake manifold and other misc parts painted with vht 2000 degree flat black my head flat black with bronze valve cover three coats of base and 3 coats clear . it looks amazing in real life .

more pics to come

Modified by CHRISTIANELIO at 12:24 PM 1/25/2010
Modified by CHRISTIANELIO at 12:25 PM 1/25/2010

[CHRISTIANELIO]

Present from fed ex !!! my main stud kit arrived today along with my eagle rods and clevite main / rod bearings !! in the next few days i should be getting my pistons , felpro gasket kit , head studs ,and my black header wrap .

Also today I picked up a n60 maf ...anyone wanna sell me a pigtail cheap ?

[CHRISTIANELIO]

some info for you fellow ka24de engine builders or newbies .

arp doesnt make main studs or head bolts for our ka engines

some places sell kits for the ka but really they are designed for other cars

arp mains are from a nissan l20 engine and then they send you 3 longer studs from another kit to make a complete kit for our ka engines

arp head bolts are from a saturn engine ..

I just got off the phone with arp and the torque specs are made for the bolt size and thread not for the actual engine .

torque specs from arp main studs -10mm bolt 60ft lbs use fsm sequence

head studs -60 ft lbs +/- 7 ft lbs use fsm for sequence

all torque specs are very important . The rep explained it like a spring once you pull the spring to far it wont go back to the original shape or size causing a weak spring . same for a bolt . so torque specs should not be over tightened .

** i really didnt know until he explained it to me .

I have done tons of research and found out some people torque their head to 85-90 ft lbs which is stretching the bolt past its limit . always use moly lube for fasteners .

[CHRISTIANELIO]

well so far i have spent on this motor build

$735 pistons and rods

$129 main studs

$100 head studs

$140 felpro gasket kit with head gasket ( will be using copper spray on it as well )bad experience with cometic .

rod bearings -$40

main bearings -$65

header wrap -$40

my machine shop charges

bore and hone 4 cyl - $60 hot tank $20

micro polish crank -$25

clean /check head -$25

One thing I am also going to do is build a amazing head from the 96 ka24de motor .

I am planning to use supertech dual spring with retainers .

with this build I am planning to make a drag car out of my coupe .

Deltacam.com has made me a 272/272 cam before for my eclipse and it was a great cam

They are custom making me a 281/281 cam

they weld and gring your stock cams for 300 bucks using your old cams . Take about 1 1/2 weeks to get it from the day you ship your cams out .

Another thing i found out it on stock cams the orange and green stripes differ from ka to ka . way to identify the cams is the intake cam dowel pin with align with the lobe and then the other cam will be the exhaust . some cams dont have the stamp I or E on them . just some food for thought

[RideNslidE]

looks good! i may have missed it but what are you doing for a tune?

[CHRISTIANELIO]

I am going to use my Greddy emanage blue I just bought the boost pressure sensor 3bar . I still want to get the injector harness and the ignition harness for it . I am also using a aem uego wideband .

[CHRISTIANELIO]

well i havent been very good on keeping this thread up . however then engine ran great with the wiseco eagle build except for when my valves hit the pistons due to my timing chain snapping putting everything back together now after buying new valves and gaskets and a new oil pump . should be on the road again this weekend .

[Lonismos14]

I am going to use my Greddy emanage blue I just bought the boost pressure sensor 3bar . I still want to get the injector harness and the ignition harness for it . I am also using a aem uego wideband .

After spending all that money your going with the emanage blue. I wouldnt do that.

at least- efispecialist.com Check them out!

Sorry if im coming off mean im not trying to. I just like to help peeps.
Modified by Lonismos14 at 4:28 PM 2/17/2010

[CHRISTIANELIO]

emange blue is a great system . i have the injector harness ignition harness knock sensor harness and the boost pressure sensor . I have all the options for the blue and with all these additions the blue will be a great tuning device .

[Lonismos14]

O i dont think so im trashing my blue

[CTS13]

Nobody uses blue anymore. Standalone or stand with a bunch of blown motors.

[WDRacing]

The Blue is crap compared to an actual ROM tune or the Emanage Ultimate. I would use a FMU over the Emanage Blue.

[CHRISTIANELIO]

right ??? blue is a goods basic tuning device . I have had previous projects with blue , and I have dialed in great tunes . user experience is needed ,so yes blue and every other tuning device is crap if you are a newb .

[WDRacing]

I'm not saying you're a noob, and I'm sure you'll get the car running well, it's just my opinion that it could be running far better given another tuning option.

[Lonismos14]

Newb or no newb

Its just a piggy back system. KEYWORD: PIGGY_BACK

Im speaking from experience cause i have one. And soon as my efi specialist tune comes in a couple days im selling it for the low.I wouldnt go over 10 psi with the blue or you are asking for a new motor.

But as always its just my opinion. GLWB