Rebuilt my KA24E

[nelson8708]

I dont post much on nico so i though i would chime in and let you guys know what i have been up to. This is going to be boosted but i though i would post it here because it is a stock rebuild for the most part.I posted this in the sohc section but i figured most of you dont go in there so i though i would share it with the rest of you. Just a few updated pics of my engine i have been rebuilding over the winter. It is getting swapped in on the 12th so i have a few things to finish up before then.

Port matched the upper and lower intake manifold and removed the secondary butterflies. I am waiting on a last few parts to come before the 12th. I have to pull 350$ out my wallet to buy the finishing parts so i will be ready for this spring/summer. Also got a FMIC so i will be running 10psi this season. Cant wait.

Here a list of the parts and prices:ITM rebuild kit(bearings, pistons, piston rings, full gasket kit, oil pump)-260$280z high flow oil pump-90$OEM head bolts-40$

Othe stuffD21 clutch and flywheel-160$JGS MM-118$

Throw in 50$ for misc. thing i got like spark plugs, wires, cap, rotor.

Just on the engine i have 390$ Clutch, flywheel, and MM-278$Misc.-50$

Total-718$ in the whole deal...plus about a 1,200 in my turbo kit.

Got some of the last second parts in. The only thing i am waiting for is the JGS MM but i dont need those until mid next week.spent a few hours working on the motor earlier tonight. I took care of some little things and pretty much finished the engine. I still need to get a pcv line and intstall it but other than the oil pan, alternator, power streeting pump that is about it.

I also finished the bung on the oil pan for the return line. Nothing like a little JB Weld. Used a cheap flux core mig welder to weld it best i could then the jb weld to seal any pin holes that were there.

Packed the transmission mount with some 3m window weld

To finish this off here are a few pics of my car. Finally warm enough i indiana that i could wash my car. I didnt put the side skirts on yet but i have them.

Comments welcome...

Modified by nelson8708 at 3:49 PM 3/16/2007
Modified by nelson8708 at 8:12 PM 3/16/2007

[intox]

inspirational lol I'm looking into rebuilding my ka24E in my black 89 hatch. I wish i could do my own work too

[WDRacing]

When you turbo it, please add all these pics and the writeup to the KAT section. We have alot of members there who will enjoy it as well. Very nice work man. Should be a really fun motor.

WD

[nelson8708]

I will keep adding pics for this week as i progress through the swap. Here is a pic i took a while back. For the most part it is still the same. With this swap i just want to clean things up.

[nelson8708]

inspirational lol I'm looking into rebuilding my ka24E in my black 89 hatch. I wish i could do my own work too

You can do it your self. This is the first rebuild i have done. All it takes is a good torque wrench, a manual, and some paitiance if i could spell it . You can pick up ka24e's for next to nothing. I traded this one for a extra right front fender i had.

[dickie]

awesome. cant wait to see it back in action, thats an interesting front bumper, i feel like i have never seen one like that before.

[nvrplzd240]

Looks good man

[StorminNorman]

Looks good man. Patience is right.......I am just finishing rebuilding my ka24de.....Not going turbo though........maybe on the next build

[tonynalli]

Ahh I remeber building my old KA-E. That was my first 240 motor i rebuilt. I was planning on boosting mine, but the car go totaled durring a hurricane. I just gave up, took a check and bought a different 240. Makes me want to go and rebuild another engine, but i have 0 space where I live. That and carrying an engine upstairs might prove to be a pain in the ***.

[nelson8708]

that is what friends are for......might prove to be worth it if you built it for turbo

Here is a up date of what i have got done in the past few days. I got a few thing done tonight. I got the oil pick up, oil pan, alternator, power steering pump, and belts on. I also got the car up on jack stands, removed the radiator, drained the transmission fluid, and removed the intercooler piping. Tomorrow i want to remove the exhaust, remove the drive shaft and get the transmission ready to remove. Tuesday i want the motor to be out and wednesday i am going to clean up the engine bay and paint it. Here are some pics of the progress.

Here are some of the goodies i got to so i am ready for beakin....STUPID SHARP ZIP TIES

[nelson8708]

got a good amount of stuff done tonight. Got the wiring harness out except for the starter solenoid hot wire. Sprayed it with some rust penatrent and hopefully it will be loose by tomorrow. Got the exhaust, turbo and turbo mani out as well. Going to try and get the drive shaft out and maybe the slave cylinder. Tomorrow the transmission comes out and prep for the engine removal wednesday. Anyways here are the pics from today.

If i can get the transmission out tomorrow i will have some more pics for you guys....later

[thekawaii]

Like your C-west DRFT bumper

[nelson8708]

thanks

got more stuff done before i go to bed. Took a serious amount of extensions to get a starter bolt out. Nothing like pulling the transmission at midnight by you self listening to rock. Good times ....tomorrow some friends are coming over and around seven or eight i should have a engine hoist and have the old motor out that night and start to clean and prep the engine bay for a little paint.Good stuff 8) When i first bought the car and didnt know much about it......... the clutch went out and i had to have a shop replace the clutch. For a stock clutch and remanufactured flywheel it cost me 1,000$.....So here is a pick of the 1K clutch and flywheel combo that i have....i got :

[lbrowne]

What was your previous setup? Everything is looking good man, props for the documentary

[nelson8708]

my last setup is the same as this one (T25, Rom tune, 7psi). This is just a fresh motor with emmisions, and secondary butterflies removed.

I have a quick question about the clutch installation...I have read that you should use high temp grease on the pilot bushing but i have also read that you should use motor oil.....which one?

BeforeAfter

[lbrowne]

I've always used the grease with no problems at all. The white lithium kind of grease for moving parts. Don't slap it on there, just fill the grooves well on the input shaft and that should be good enough.

edit how many miles were on your KA running that setup and for how long? This was also with the 460 injectors...stock MAF?

[nelson8708]

I was talking about the pilot bushing that goes in the crank shaft. Not the clutch splines. But could i use blue high temp wheel bearing grease for the splines?

Actually i was running the stock 270cc injectors with a fmu on the other motor which had 144K on it. I just ran low boost. I have the 460cc injectors and every thing i just wanted to wait until i got this motor in to put them in.

[ivorywhite240sx]

Nice going, Good work,....Im new to this site and saw that you have done something that i have been thinking about lately, I might need your help on where to buy the complete engine rebuilt kit for turbo?........thanks

[nelson8708]

I didnt rebuild this engine for turbo...it is just a stock rebuild. For parts you cant beat jgsturbo.com and turbo240.com......

got her in today. Since i was with my self i had to fight it for about 30min but other than that it is good. Here is a tip for any one installing the jgs mounts......take the driver side mount and bolt one half to the car and the other half to the MM and the MM to the engine. This way the engine will just slide into place. Then bolt the two halfs together. This way you dont damage the threads on the stud that goes through the motor mount like it did .....o well. Flywheel and clutch go in tonight and the transmission hopefully tomorrow. Here are the pics

Later

[BMAR240SX]

This is what i call p0rn Rock the sohc's

[S13DrIfTmEkAnIcS]

<3 one of the best single cams i've seen. i'll be rockin a little part of my fallen single cam in my dual cam. lol single cam pistons do a lot for the dual cam. love the work tho man, good job

[nelson8708]

thanks for the comments guys...yeah i know a buddie who i am trying to convince to use my sohc pistons in his dohc for a fun daily driver. Clutch is in. Had to cut part of the spacer that goes in between the engine and trans so it doesnt grind on the back side of the flywheel since it is the white bunny special setup.

[lbrowne]

Actually i was running the stock 270cc injectors with a fmu on the other motor which had 144K on it. I just ran low boost. I have the 460cc injectors and every thing i just wanted to wait until i got this motor in to put them in.

So the sohc has 270 injectors stock, you had a fuel management unit (what did you run?) and how much boost is low boost? 5psi? 7psi?

Sorry for the barrage!

[nelson8708]

actually this is kind of funny but the turbo i got had a bent waste gate rod so the spring was held compressed when it was in storage. So when i straightened it out the spring was a lot weaker. Beacause of that i am on 2psi. Which didnt bother me at all i was actually glad it was that low. Yes you could still tell a difference. When i ran the quater mile i had my stock clutch and worn motor mounts so i didnt launch it at all. Keep that in mind.

15.2@93mph with a 2.65 60'

I give my self benefit of the dout that i can launch the car because most 240's can put down a 2.2 60' or even a 2.0 with some good tires. So it is in the mid to upper 14s. From a roll i have pulled a few 14.7 cars. I would have raised the boost but the fmu i got was a 12:1 and that would send my fuel pressure through the roof at boost as low as 5psi. At 5psi my fuel pressure would be 103psi in the fuel rail and that is too much for the rubber lines in my opinion. If i had a 8:1 i might have turned up the boost. I about a month i will put on the new waste gate actuator and throw a base rom tune on it with my 460cc injectors and then run 7psi. The reason i didnt tune the last motor is because the manifold i made had too many pin holes in it (flux core welder) and the wide band was reading 45:1 at wide open throttle on the 2psi with fmu even though i know i am in the 10:1 or richer area. Black smoke at wot tells the truth. I am making a new turbo mani and it should be done in the next few weeks. Then i will tune it.

[nelson8708]

got everything in today and hooked up. However it wont start. Well it wont crank. When i took the strater off the top of the solenoid spun with the nut and that probably broke off some wires internally. I can hear a clicking so the solenoid might work but the starter doesnt. So i have to go to auto zone and get a new one for 100$. Damit that is my whole check for this week from work. I dont care as long as it starts up and runs so i can go back to school next week.

[BMAR240SX]

Dude can you record the start up

[nelson8708]

too late for that but i am having some problems at the moment. I will get some vid of it when i get it running properly. I need some help at the moment.

got it to start but it was idleing really rough. I had to hold it at about quater throttle to keep it idleing. After about 20-30seconds of that it would idle by itself but still rough. Then i got out of the car and saw that my turbo manifold was cherry red...not good. So i killed the car turned the heat on, my electric fan on, and put a box fan over the turbo to cool it. Hope i didnt fry my turbo. So after it cooled i started it agian and as soon as it started i went and moved the distributor and tps sensor and got it to idle smoothly but now my manifold has a crack in it that i will weld.

Q: What i want to know is if the timing is what caused the manifold to turn cherry red?

If the timing was way retarded would it cause that. It seemed like there was a huge load on the motor even though there was none. Tonight i will weld the cracked manifold and tomorrow i will time it and set up the tps. I hope i didnt fry the bearing in the turbo or cause any damage.

[lbrowne]

I've definitely heard of glowing manifolds with improper timing. Wasn't on a turbo car but, it's still a combustion motor.

[nelson8708]

from what people are telling me on other forums it seems to be that i was running really really advanced timing. I might be off a tooth. Tomorrow i am getting a timing light. Thank god i didnt melt a piston .

[nelson8708]

it was off by a tooth but it was not advanced to far it was way retarded. I was running like 20 to 25 degrees ATDC. Here are some pics and the end of my story thank god. Had motor in and most everything done. Still needed to put the exhaust on. Finally got all that stuff on and went to crank it and nothing happened. I knew it. When i took the starter off the top of the solenoid spun with it and that broke some wires off inside. So i go to advanced auto zone and get a starter that day for 105$. :roll: ...i am out of money.....Get the starter in and she cranks over but runs horable. That was when the timing was off and the manifold cracked from being cherry red. So i go and pull the turbo, manifold, and exhaust off so i can weld the crack. I finish that and get every thing back on. Now i have to fix the timing issue. It is easy to do that on a DE but with a E you have to drop the oil pump and shaft and turn it one tooth which is a ***** by the way. That took me probably a hour because i thought i had it and droped the car but it was still off. ....So i get the timing fixed....set the tps....and time it. She runs a lot better but there is a lot of valve train noise. I was thought that it was might be f*cked. So i let it warn up to temp and shut her off. Change the oil and filter then primed her agian and started her. The valve train was much quiter. So at this point i believe i am done. Finish up a few loose ends and call it good. I have not driven her yet but i am going to after i get something to eat (havent eaten today). Hope that part goes well. I guess only time will tell weather or not i screwed the motor with that timing issue.

Pics are in order with the events that happened.

Later

my little side mount