KA24DE Emissions Equipment 92/95 swap?

[evlzer0]

I have a 1992 240sx That had a blown motor, I swapped in a 95 KA and so far everything has worked out pretty good. Im down to hooking up my emissions equipment at the rear of the engine (EGR Valve, etc.). I have noticed that the 95 EGR setup is different than the 92. The wiring harness connectors are different as are the vacum lines (2 on the 95, 4 on the 92?.) Theres no SCV on the new motor which i believe was one or two of the 'missing' vacum lines and Im guessing that also accounts for the extra plug on my wiring harness too.

My question is, what are my options? Do I have to swap the 92 Emissions equipment onto the new motor and go from there or is there something else I can do to make it work? What parts am I required to have for smog tests, and which can i leave behind (if any)? Im moving to California within the next month, so as far as i know I need some of this stuff.Any help would be appreciated, thanks.
Modified by evlzer0 at 12:45 PM 11/5/2005

[evlzer0]

Looking around the garage i found the cut up engine harness that came with the 95 motor. I figure i can just take the EGR harness connector and splice it onto the 92 harness EGR connector. Will that work? Ive also found a Vacum line coming off of a line that runs between the Intake Manifold and Pressure regulator, I cant find in any of my manuals where this goes. Id take pictures but no camera.

[NISTECH]

You should notice on the old harness the wire colors are the same for both years. You can cut and splice it on. In california the law requires if your do an engine swap to a newer engine all the emissions components must be for the newer yr car. The evap system is the biiggest difference between the 2 cars. your 92 had a canister under the hood the 95 had more components to the evep system and the canister was located in the rear. Your best bet with this would have been to leave all the 92 components in tact and swap the intake and exhuast from the 92 onto the 95 long block. This would have eliminated the need ofr messing with harnesses and such. Since you are in this situation though. You need to be sure all the 92 components are in place and working. Also if you swapped ecm's you need to make sure it doesnt through any codes. as long as the light doesnt come on during the test and all emissions components are hooked up and working you should sail right though the test. Providing your tail pipe readings are in specs. I do not advise getting the test done at a dealership as the smog tech may notice the engine differences. Go to a corner smog shop were the techs are not as familier with the product.

[evlzer0]

Thanks for the reply,Had I known I needed to swap the intake out this would have been much easier when the engine was out of the car. I must have missed reading about that before the swap, My mistake. Ill wire up that connector and get that hooked up. Ive also connected the Vapor lines to the canister as per the FSM. Everything is hooking up good now other than this stray vacum line coming off of the line between the Intake manifold and the Pressure regulator at the top rear of the intake. I can not seem to find this in the FSM and it seems it may not be necessary. Although I would hope to find out for sure before i remove it. Ill have to wait for my new EGR pipe, broke my other one getting the engine out of the car, before i can start it up and make sure everything works properly. Thanks again NISTECH, you have been very helpful.

[NISTECH]

I am guessing it goes to the scv that was on the 92 intake manifold. If you have the factory service manual you can find the hose routing on page EC-8 and a picture of it on EC-11.

[evlzer0]

This was left on the 95 Intake manifold. It is a larger hose than the rest of the Vacum lines. There is a Vacum line coming off of the larger hose. Meh, If i cant find it ill just take it off and see if it works without it. Wednesday Ill be starting it up and hoping this swap went as good as it seems. Thanks for all your help Nistech.

[NISTECH]

Do you see it in this picture. This is a 95 240 vaccum layout diagram.

[evlzer0]

Ive colored the hose red in this picture.

I believe this is another angle of the same place, also colored red where the hose should connect.

Every image i see in the FSMs show it as one solid hose, but I can never find a name or description for it. Mine is rather 2 hoses connected by a 'T' connector with a 3rd smaller diameter line branching off. This third line is just hanging in the engine bay.

Im sorry I cant take a picture and post it, I dont have a camera. Ill try and snake one from a friend if i can, this has got to be a pain to follow without a real picture. Seriously, thanks. I dont think I could have gotten this far without the help of NICO.

[NISTECH]

Well the fuel pressure reg needs to go to manifold vaccum source. Why there is tee's in the line kinda stumps me, maybe you have the wrong vaccum line on there?

[evlzer0]

Allrighty,Everything hooked up now, got my EGR tube and had a PITA time getting that swapped out but its done. That Vacum line isnt causing any problems so thats no longer an issue. Filled her up and got my last pieces all connected. Started up first try, we could hardly believe that . No check engine light, just gotta get some better gas in it and Im good to go. Only thing is that it idles at 1400 (reading this forum i can say its most likely that vacum line with the "T" connector causing a leak) but that seems minor after everything else. Thanks alot for helping me make this happen.
Modified by evlzer0 at 7:09 PM 11/10/2005