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Henry's SR20/240 Progress... in photos. 56k, you have been warned.

85K views 510 replies 96 participants last post by  brokenarrow33  
#1 · (Edited)
Well, I get enough questions about my own swap and what progress I've made (if any) that I figured I might as well start my own thread. This way I don't need to hijack go240's progress thread.

go240's SR swap thread


1990 240sx Fastback
SOHC Pignose Power!!!

Thread is getting quite large... this should help (added 8/21)


  • [*]Page 1 - KA Removal
    [*]Page 2 - Parts
    [*]Page 4 - Parts, Engine Bay Prep (Frame Rails)
    [*]Page 5 - Frame Rails Painted
    [*]Page 6 - Battery Tray Removal, Engine Bay Paint Test
    [*]Page 7 - More Battery Tray Removal Info, Engine Bay Paint Test
    [*]Page 8 - Engine Bay Painted, More Parts Arrived
    [*]Page 9 - Parts, Parts, Parts, T25/T28 Comparison Photo
    [*]Page 10 - Manifold Install, Valve Cover Powder Coated, Cluth/Flywheel Install
    [*]Page 11 - Motor Installed, More Parts
    [*]Page 12 - Even more parts
    [*]Page 13 - Parts, Parts, Bumper Support Ideas/Examples
    [*]Page 15 - Wiring Done
    [*]Page 16 - Vacuum Lines Done, Parts, Start up Video #1
    [*]Page 17 - Startup Trouble, Startup Video #2
    [*]Page 18 - Compression Test Numbers
    [*]Page 19 - Speculation
    [*]Page 20 - Misc Photos, More Speculation, Engine Bay Paint Information

Just a few random photos of the car before the swap. I didn't have to do anything to the car, although I bought a wingless/wiperless hatch to replace my orignial hatch with that horrible foam wing. The fender had minor damage so I picked up a replacement as well. :thumbsup

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About 5-6 months ago I put in about half a tank of premium, and parked her for the swap. I didn't actually start the process of pulling the motor until Dec because of work.

December 2004

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Feburary 2005 Look at all that progress! :eek4:

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Discussion starter · #489 ·
Whatever you can get would be fine, I'll take a look at an interior lighting shot to get a better idea of it all. And then hopefully, the car will run soon and then you'll be taking all sorts of pics of the engine bay outside etc.:thumbsup

Thanks again.
How's 4 months later? :gaylaugh I didn't forget.. just busy as usual.


Here is the OEM paint in a spray can. I made sure you can see the item number and the brand of paint it was. I didn't use this for the engine bay since I found something cheaper at the autopart store. I'm saving this for the fender I'm planning to replace on my 240.

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This is what I used on the engine bay...

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Product Information...

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Here is a comparison of the paintcap to the (dirty) OEM paint on the 240. This is with the garage lighting.

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Since it's winter and the weather has been shitty I've been playing with the STi a lot. :thumbsup Hope to get around to really giving this a proper update.
 
Discussion starter · #487 ·
Thanks for the update man, I'm glad I saw that you were online today.

Seems like you've kept yourself busy with everything else. I really like your car man, maybe it's because we both share a pignose, white, fastback that soon will be boosted.
Yeah she'll stay a pignose. Too many 91+ 240's running around here. I need to spread the pignose love.

You wouldn't happen to know the brand or paint code for the white you used in your engine bay, would you? I hate to have to ask such a specific question, but then again, I'm trying to achieve an engine bay much like yours, so hopefully you'll understand and take the complement lol.

Also, would you by chance be able to take a comparison shot of the paint in the engine bay compared to perhaps your fender? I love how clean the white turned out, but I just want to be able to know what to expect with my bay as far as being slightly off, so I was just hoping for a guage.

Here is a list of all the paint codes. Yours is also a 90?
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Like I mentioned I bought some OEM paint in a spraycan. I don't recall who I bought it from but many online places can do this. I never ended up using it on the engine bay since I was going to try and spray a fender I bought. At the local autopart store I found something very similar to the OEM paint. If I still have the can I'll let you know.

I can take a comparison pic but the car is in a garage so with the lighting you might not get a true comparison.


I wish I knew SR's, just so that I'd be able to throw some ideas out there, but unfortunately I don't.

Pics of the STI? edit...damn, took too long to reply. Looks good bro
I'm a posting ninja. :thumbsup
 
Discussion starter · #485 ·
Haven't taken many pics of the STi. Bought it used from a teacher that put the wrx wing on it to make it look more grown up... lol. I'll eventually get the STi (park bench)wing back.

As it sits now.. Stage 2, DP, swaybars, springs... 297whp/301whtq (dyno'd)

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Up next... exhaust, rims, and a protune.
 
Discussion starter · #484 ·
In the meantime I've been working a lot on my GF's WRX. :)

That got me thinking I need another car.. so I bought a white (FTMFW) 05 STi. :D:D

Having 3 cars for awhile seemed pointless even though I only had 1 car payment. Since I still really wanted to finish the 240 swap I had to sell the GSR. :(

Last time the GSR and the 240 shared garage time.

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Building up a car is extremely fun... but taking apart a GSR, or any project car you've spent 5 years building.. is not fun at all. :tearsSelling it with the mods is financially stupid so I took a few days ripping her apart.

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I would get bored of exterior stuff so I would jump to interior for awhile. Good thing I know this car inside and out.. or I might not know where half this shit goes. :eek4::eek3dance

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Discussion starter · #483 ·
:16wtfOh my god...i ust spent the past 2 days reading this whole post because im really really thinking of doing the SR swap im just waiting to make enough money for parts....i read this hoping it would inspire me to do it....but im real suprised it all ended in heartbreak,:( i cant beleive after all that it didnt even fire up...im kinda sad now and i feel really bad for u Henry....ireally dont know what to say....i dont even know whether to do the swap myself or not:mad::mad::mad::131furiou
:rotflmao Don't feel bad for me. Aside from what I say this has been a lot of fun. I knew it would be a slow process but not what it turned into. It has always been something like a side project. I also waited to buy parts before the engine went in which took some time. When I finally got around to installing the engine I didn't have much free time (work/school). Since it's not my only car I'm not pressured to finish it.

If you have the time, money and work space to do your own swap I say go for it. It will take longer than dropping it off at some shop and handing over $1k, but the experience you'll gain is priceless. When you want to upgrade in the future or change something like a clutch.. you won't think twice about paying someone else to do it. Just make sure you take your time and label things as you go. I have 3 tupperware tubs full of labeled plastic baggies with misc parts.

Working on your own car is half the fun of modding cars.. no?:12dunno
 
Discussion starter · #482 ·
Update:

I haven't given up on the project but I also haven't put much of any time towards it. I took the summer off from school to enjoy myself and catchup on other things I've been meaning to do.

Wild_maxx came over one weekend and we screwed around with the engine for awhile and I got the bright idea of just pulling it out and putting one of my other engines in. We swapped 90% of it in one night and I didn't get around to finishing it for another few months.

With the new engine in the car does the exact same thing. :( I'm glad to know it's not the engine but maybe something in wiring? The fuel is pretty old at this point but I'd imagine it would still run if everything was correct... just not run very well. The fuel pump is still the stock unit and that will be the next thing I replace.

If that doesn't change anything I'll pull the wiring out and look over every plug.

I'll update the thread with some photos and maybe a video or two and we'll see what happens.
 
Discussion starter · #463 ·
Well summer is over and so is much of my free time with all my homework now. I haven't touched the car in 3 weeks but the next chance I get I'll fuck with it for awhile and see what else I can figure out.

It's stored in the garage this year so she is safe and sound. :D
 
Discussion starter · #456 ·
A bad ignitor chip would would keep the spark plugs from firing, correct? Or should this also be something I should replace?

FYI I'm using a Q45 Ignitor Chip... and modified the wiring correctly.
 
Discussion starter · #455 ·
Of course like usual I've been too busy to work on the car much lately.

I did throw on a different fuel rail with another set of injectors and tried that with no real significant changes. Popping, backfire, etc.

I pulled the manifold, turbo FMIC and checked eveything over and put it all back to make sure it was tighten properly as well.

My next idea is to pull the wiring harness and recheck everything. Although seeing as everything in the car appears to be working I don't expect this to be the problem. Sort of running out of ideas so might as well give it a shot.

Shawn I feel your fustration man.. :D I'm just glad to have my car back and working on it again.. it's all good.

Thanks for the site minime.
 
Discussion starter · #445 ·
:rotflmao A little too late for that, I've already placed an order for a Tanabe Concept G Blue exaust. Post them up anyways, make me regret my choice lol.
Regardless how sweet my exhaust may sound.. I still don't like having a 4.25-4.5in tip. Sure it makes fisting my car much easier but it's a little too big for my taste. I'll live with it though. :dancingna
 
Discussion starter · #442 ·
We did test those out. They are getting a pretty strong spark to them. Henry, get a fuel pressure gauge like we talked about online, check pressure, pull out the fuel rail and see it its leaking out of the injectors. (turn key to on) Your CAS is correctly installed so maybe its something to do with your wiring that is not allowing it to fire. Good luck buddy! :D
Yeah yeah.. I'll pickup a FPG this week and test that out. I'm really tempted to pull the wiring harness and triple check everything but aside from not firing, everything in the car works and I'm getting no codes. :12dunno

We'll see what the FPG test shows.
 
Discussion starter · #438 ·
Got the parts from Nissan and the leak is fixed. I tried starting the car with no luck. After trying to start it 40-50 times over the past 2 weeks or so the oil had a really strong smell of gas so I dumped it. So I'll need to pickup some fresh oil tomorrow.
 
Discussion starter · #435 ·
Well the local parts store had no clue what it even was.

The black seals in the pic.


Injector insulator Jan 1991 - Dec 1998 16635-53J00
Injector rubber back cap Jan 1991 - Dec 1998 16619-53J00


Which would it be? I'm guessing the Injector Insulator from a 91-94 KA24DE engine.
 
Discussion starter · #434 ·
Thanks for checking bro.

I'm going to stop by an auto parts store on the way home and see what they might have. Someone mentioned the KA24DE should share the same rubber seals. The closest Nissan dealership is about an hour away and it should be a little cheaper.

I think when I bent the original fuel rail I left it on the motor too long and it pressed against this seal and must have eventually warped it just enough to let fuel by under pressure. :12dunno

Hopefully this leak is causing the engine to flood and not fire, or the a vacuum leak from the seals is causing a problem. We'll see..
 
Discussion starter · #432 ·
I took the time to read this whole thread and it was great... i noticed that i am going to be doing sorta the same swap and buying most of the same parts (only diff is mine is a s14) which may throw off some of the stuff in here but it was still very helpful to read. Its kind of depressing watching you build up a beautiful red top and then have trouble getting it running ( it actually really worries me) :(
But good luck and i really wanna see a good video of you finnaly firing her up
Glad to know you liked the thread. I try to make it as informative as possible. There are other builds out there that really got me motivated to do mine and influenced me as well.

Don't be worried about running into problems. Just know that they will happen so you won't be so suprised when they do. :thumbsup You can't expect to build up a car and not run into issues... just be prepared. This board is a good resource for information and the members here are great. My car will eventually get figured out and hopefully yours will get running without and problems.

If you want to read about a build from hell that also got figured out...

http://www.240sxforums.com/forums/showthread.php?t=13351&highlight=rexbo

Rexbo is a great guy and now knows a ton about SR's after doing his build. :supercool