Fully Built KA24DE S13 Build Thread

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airman86
Posts: 320
Joined: Wed Feb 11, 2009 4:55 pm

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I have been slowly piecing this build together for almost two years now and I have finally gotten through a lot of progress with getting it together. I have an old, outdated thread buried in here somewhere but I felt it would be best to start a new thread since a lot has happened in the past few months.

I got a longblock off of craigslist about a year and a half ago, and built it. I was one day away from picking up a '92 hatch, had the money in my pocket, but a loan from school didn't come through and I ended up having to put that money towards school instead. So, long story short, I haven't had the money to get a car. Until back in June.

Even though I didn't have the money, I checked atlanta, greenville, and charlotte craigslist daily for a suitable car, for dreaming purposes. Eventually, I decided to check Nicoclub's classifieds list, and found a thread for this car.

The body is decent, interior is as clean as it can be. Crackless dash, no tear in the drivers seat. Came with front and rear sway bars and what looks like a set of 2" lowering springs, still wrapped in plastic.

As you can see, it's a pignose. The engine that was in it and supposedly ran before some wiring issues arose. THE BAD: it's an automatic, which means a little more work to do the swap. Either way, I couldn't pass up the deal. $500 got me the whole thing.

My goals are 400whp-ish daily after I go turbo. The build so far includes:
KA24DE motor bored 0.020" over
Wiseco 9:1 pistons (i think)
Eagle H-Beam rods
ARP head and main studs
Clevite rod and main bearings
Fully balanced rotating assembly


Onto the car:

with my lovely DD in the background :P
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excuse my shirtlessness. Supposedly broke 100 degrees that day.
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No rust! (well, surface rust, I could wipe it off :P)
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Original sunroof cover. I've been told that these are rare!
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Yep, it's an auto. I'll get over it once i've got the 5sp swapped over :P
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Clean single slammer motor! Sale pending.
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Last edited by airman86 on Fri Nov 12, 2010 7:22 pm, edited 1 time in total.


airman86
Posts: 320
Joined: Wed Feb 11, 2009 4:55 pm

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Now, onto the engine build:

On the ride home from the machine shop - buckle up
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The head in the garage:
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Block on the engine stand and primed, painted with semi gloss black.
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Engine paint to tie into the high-gloss brackets and other stuff. This is only about half of them.
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with just me doing this build and no extra hands it's hard to take pictures while my hands are covered in grease and i don't have a cheap camera (digital slr) and i'd like to keep it clean.

I started off by wire brushing and thoroughly cleaning all the bolts:
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Sanded off excess gasket to ensure a smooth surface on the oil filter assembly:
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Crankshaft in:
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Head studs in:
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I'm pleased with the bore and hone-job:
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Oil filter assembly on:
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Rods:
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Putting on lowering springs
front springs on! nearly wore myself out on the spring compressor, so the rear ones are coming on a different day heh.

roommate with some helpful hands
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spring compressing
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difference between stock vs new
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i'm thinking about going with these rims...not really
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new boots
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checking fitment
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and magically the fronts are on!
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The rotating assembly has been balanced and it looks pretty good. The guy had it done in a day - glassbead and polish the crankshaft, R&R on the pistons, and fully balancing the rotating assembly. $220 for it all.

Anyways, I am taking this week off to get as much done as I can. At this point i had the bottom end of the engine put together, plastigaged to spec, front cover and lower timing chain on. I have the '91 cams I was gonna put in, but I left them ~40 miles away at my apartment (Doing all the work at my parents' house, I left all my big tools here).

I picked up a new, complete transmission, driveshaft, shifter, and I went ahead and got a replacement hatch as well. The one that is on the car already has really bad rust and the wing holes were rotted out.

Couple of pictures:

CRANKWALK! (my roommate has a turbo eclipse, he doesn't know it but I took this for him)
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Just about perfect:
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Most of the engine put together:
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airman86
Posts: 320
Joined: Wed Feb 11, 2009 4:55 pm

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going wingless

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A little teaser:

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Everything put together. Had an issue with the timing because I'm running dual exhaust cams, as well as broke a camshaft cap bolt off inside the head which was a little pain to get out.

The only relatively complete SOHC > DOHC swap guide that I can find is here on Nico, but there are no pictures and it can be a little vague. If anyone knows of any other resources that are simple, I'd love to check it out. I'm also swapping in a 5speed, but I have one of the 240sx tech dvd's for that that seems to be well done.

Update with a few pictures:

Yankin out the old garbage: (sale pending)
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Dirty bay soaking in cleaner:
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Pressure washing everything:
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Clean bay: (the black stuff inside the transmission well won't come off...looks like bedliner or something :P)
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In with the new:
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In place: (the upper timing cover has been since cleaned and now matches the head)
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I decided against running power steering or AC for now. Ran into some confusion on the power steering stuff since I'm swapping SOHC to DOHC. All the guides say just to get a new line, but it looks like I'll have to get one custom or get a new rack - which I don't feel like doing - same with A/C. Haven't had A/C for probably 2 years now, so I'm used to not having it :D

The car is at my parent's house in Greenville since I didn't have room to take all of my tools (mainly the lift) with me when I moved out into an apartment.

At this point, this is where it stands. I had to stop here because I didn't have the rest of the DOHC swap parts (maf, distributor, coil, etc). I will be going home this weekend to hopefully finish it!

fame_s13
Posts: 103
Joined: Sun Jul 18, 2010 9:23 pm
Car: 1997 S14 KOUKI
2008 SCION tC
Location: Ohio!

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great build! good luck!

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Philipio
Posts: 1150
Joined: Thu Aug 31, 2006 1:35 pm
Car: 96 240sx, 96 Miata
Location: DFW, Texas
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I didn't read anything about a turbo? You only referred to the engine as being naturally aspirated from what I saw skimming through. If you want to do a naturally aspirated build, sorry to burst your bubble but you will never reach 400whp.

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truckmtr240
Posts: 290
Joined: Thu Aug 27, 2009 4:26 pm
Car: 91 240sx hatch
Location: Lancaster

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good job cleaning that up!

airman86
Posts: 320
Joined: Wed Feb 11, 2009 4:55 pm

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Philipio wrote:I didn't read anything about a turbo? You only referred to the engine as being naturally aspirated from what I saw skimming through. If you want to do a naturally aspirated build, sorry to burst your bubble but you will never reach 400whp.
I've made it this far but you think I'm too ignorant to know that? It's going turbo, just not yet. I thought that's in the description up there somewhere.

Anyways, while putting the electrical together, I found that the MAF connector has been cut off of the harness I bought! Son of a b****. I guess it's the time to switch to an N62 MAF in prep for turbo...either that or find the stock plug for this MAF.

Bah, setbacks. Thanks for the rest of the comments guys :)

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s13_chris
Posts: 965
Joined: Sat Jun 09, 2007 6:45 pm
Car: 90 240sx Hatch

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Bummer on the plug. I'm pretty sure you could source one out somewhere! Part outs, Junkyards, craigslist, etc etc. Just look around! Sorry if I'm mistaken but I don't remember reading about wheel plans?

airman86
Posts: 320
Joined: Wed Feb 11, 2009 4:55 pm

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No wheel plans yet. Gonna run steelies for now while I'm N/A and then find some wheels when I go turbo. I'm gonna want at least 255s but I'll probably step up to 285, then throw the steelies back on for drift/autox. I have no idea what kind/brand. I can't decide...

I hacked up the SOHC MAF plug (3 pin) and made it work with the DOHC MAF.

To do:
Finish wiring for SOHC > DOHC swap
Finish wiring for Auto > 5 speed swap
Wiring for electric fans
Find where random hoses/vacuum lines go

Ignition!

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SX APPEAL
Posts: 1345
Joined: Tue Oct 05, 2004 10:26 am
Car: 06 G35 Coupe 6MT
95 Maxima SE 5MT
Location: Springfield, MO

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If you're planning to auto X with a 400whp turbo, you're gonna want the 285's for that, not steelies with cheap 195's, just sayin...

airman86
Posts: 320
Joined: Wed Feb 11, 2009 4:55 pm

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It's not really an official competitive Autocross. It's a club at my school that usually has 30-50 cars that race on a small course. If it was for true competition, I would keep my DD tires on there. 285s are expensive!

KavVeMan
Posts: 50
Joined: Sat Oct 19, 2013 1:52 pm
Car: 1991 240sx rb25det swap
Location: utah

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is this a dead thread? cuz im thinking of doing the same thing minus the 5 speed swap cuz mine is a stick anyways could use some help with this and some good ideas.

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pepesilvia
Posts: 584
Joined: Tue Feb 21, 2012 8:15 pm
Car: 96 S14
Location: New Jersey :(

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this thread is 3.5 years old.... probably very dead. Use this dude's website,http://www.240sxtechdvds.org/index.html he's got DVD's on rebuilding the KA and SR's and stuff. I bought one of his DVD's for 5-speed swap and it was VERRRY helpful.

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krash
Posts: 4836
Joined: Mon Apr 11, 2005 10:43 am
Car: 1993 Nissan 240sx Convertible
Location: Memphis, TN
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I've got the same exact internals as the OP, car is running neat. If you dont want to pay for the DVD, I've made my own installation videos. Check out projectgarage.net for those


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