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View Full Version : Swap in coupe complete! tutorial + pics


PSI240SX
08-31-2003, 10:57 AM
Well guys it finally runs!!! Got the motor in my coupe running last night after 7 hours of work friday and 12 hours yesterday. Whew am I tired and sore....

I have pics and tips for anyone swapping, check it out!

Here is the platform....

http://www.planb-attack.com/Jay/Lake2.jpg

It's really missing an IC with that aggressive front end don't you think? I didn't drive it at all with the SOHC... it has been sitting under a cover at my boss's shop for months. I got started by putting the car on my ghettolift pictured here:

http://www.planb-attack.com/jay/Silviaswap/GhettoLift.jpg

and pulling the front bumper off to make room for the Greddy kit:D Thanks ENJUKU!!!

http://www.planb-attack.com/jay/Silviaswap/comingtolife.jpg

I dropped the motor in about 2 months ago but was out of money so I couldnt get it running at that time. This weeked I had to: Install IC, run the pre-modified harness, remove turbo and re-install larger one with HKS 02 housing, install testpipe, downpipe, exhaust, Custom PS line, Radiator, elec fan, belt fan, relocate battery, change fluids, install shifter. Spent about $2300 in parts this week to make sure I could get it running this weekend.

I bought this exhaust from Ebay, that guy SSAutochrome that sells mad cheap stuff all the time on ebay:

http://www.planb-attack.com/jay/Silviaswap/Exhaust.jpg

It's 3" polished stainless steel with no resonator and I got it for like $219.50 plus shipping. I like it a lot, nice and loud! Here it is on the car with the stainless cat and downpipe from Enjuku...

http://www.planb-attack.com/jay/Silviaswap/AllStainless.jpg

What I really like is that it doesnt hang down and scrape everywhere like my N1 on my sil-eighty:

http://www.planb-attack.com/jay/Silviaswap/Exhaustoncar.jpg

I also got a SS tubular exhaust manifold like the one ssautochrome sells pictured here:

http://www.planb-attack.com/jay/Silviaswap/SSmanifold.jpg

Since my car was an 89 I had to locate a PS reservoir from a 91-94 and also the PS line... I got a line from a buddy who cut it out of the car so I had to have a brass fitting braised on to join his half and my half together to make it work:

http://www.planb-attack.com/jay/Silviaswap/PSline.jpg

I also bought an HKS turbo (o2) housing and I cut and modified it so that when the wastegate opened it would vent the exhaust straigh out instead of through the exhaust, here are pics:

http://www.planb-attack.com/jay/Silviaswap/Dumpipe.jpg
http://www.planb-attack.com/jay/Silviaswap/Dumpipe2.jpg

This didnt work quite like I had expected unfortunately.... I am removing it today and replacing with a stock one til I get it fixed. I failed to realize that even though there is a block off plate between the two openings (turbine and wastegate) it is not completely blocked off so there is a huge exhaust leak. I will have to actually plum it back into the exhaust so it will quiet down. Oh well... live and learn.

Here are some tricks to remember when doing a swap like this using a FMIC and stock o2 extension, and rubber turbo outlet:

When using a FMIC kit like the greddy there is a pipe coming off the hotside that has a little tube that is open for the stock recirc valve, when using a BOV you need to block this and I found a cheap easy way. Go to discount auto and buy a rubber freezeplug, package pictured here:

http://www.planb-attack.com/jay/Silviaswap/Freezeplug.jpg

It was actually a tad bit small but I made it work nonetheless. You insert it in the hole and then tighten it down with a wrench so that it expands and fills up the hole like this:

http://www.planb-attack.com/jay/Silviaswap/Freezeplug2.jpg

On to the next trick. When installing a SR using the factory o2 extension you will need to remove the egr hose to clear the PS linkage. After removing the tube cut it with a hack saw and remove the nut that you unscrewed out of the o2 housing. Now you have a big hole there.... what can we use to plug it??? Got a nickel?:

http://www.planb-attack.com/jay/Silviaswap/Nickel.jpg
http://www.planb-attack.com/jay/Silviaswap/Nickel2.jpg

hahhah yeah its a perfect fit! Just place the nickel in the hole and screw the nut in and voila! no more exhaust leak.

And finally the stock rubber turbo outlet that goes to your maf will have a big hole in it for I dont know what but it can be plugged with a bottlecap from a soda and a hose clamp like this:

http://www.planb-attack.com/jay/Silviaswap/Bottlecap.jpg

Anyway, it went fairly smoothly, no real problems, except when I went to start it lol....

No fire over. Check fuel, no fuel. pull fuel rail to make sure... nothing squirting. Keep scratching our heads trying to figure out. Called my buddy Noah and asked him... first thing out of his mouth was "Is your ecu plugged in all the way?" I looked at Eric and asked if he plugged it in and he said I thought you did it! Well I thought he did it but it turns out no one did lol. Plugged it in and vroom! Went out pimping it last night looks real friggin hard with that bomex bumper and huge IC behind it now.... I will have more pics soon.

einherjar
08-31-2003, 11:34 AM
nice!

yeah i just finished mine yesterday, oh and dammit! i thought i was the only one to think to use a nickel for the AIV hole.


hahaha.

Rittmeister
08-31-2003, 12:34 PM
Very nice! I need more money to start my own swap...

Kid Zelda
08-31-2003, 01:26 PM
Ahhh, the macgyver mod's .. gotta luv'em

JerkFaceJason
08-31-2003, 02:38 PM
isnt that hole in the rubber part (with the bottle cap) for the vaccuum line that needs to go from the beginning of the TB to the intake? i heard the car runs alot better when you have that connection

Kid Zelda
08-31-2003, 04:07 PM
Originally posted by JerkFaceJason
isnt that hole in the rubber part (with the bottle cap) for the vaccuum line that needs to go from the beginning of the TB to the intake? i heard the car runs alot better when you have that connection

That's for the bov to recirculate, but PSI went fmic and atmos' bov, so that "hole" gets cap/plug with pepsi cap

stealthj
08-31-2003, 06:25 PM
congrats man, looks real nice, if only i could find a 240....

720_datsun
09-01-2003, 11:09 AM
Originally posted by stealthj
congrats man, looks real nice, if only i could find a 240.... hey me too.

moto
09-02-2003, 12:53 AM
I can see my feet in pic 5 :)

glad its running Jay. Now if i would stop running into problems maybe i can get mine running and boost along side of ya.

ijon03
09-02-2003, 12:56 AM
:aw: Hes car look good man i just saw it today as i get his SILEIGHTY:boink: he wouldn't let me trade with that one.

Jay i get home safe an sond alltough very tired as i drive straight home for 9 hours.
Man the car handle just as you said very tight cause on the way home near Chattanogga there this curves mountain road and i drive it hard and it went as it is on the rail. But very hard turning in the city.
Could you tell me how to make the PS working(or did it work before?)

Thanks Jay
Ijon

ijon03
09-02-2003, 12:58 AM
oh uh by the way my ather S13 for sale
see 91 240SX SE with SUPER HICAs thread.
:axe: :D

ijon

PSI240SX
09-02-2003, 05:57 AM
the power steering was working fine.... Did you check to see if it threw the belt?