My first 240 drift build

[JRusty15]

Picked up my first 240sx a few weeks ago with the intentions of building a missile car to take to some local drift events and have some fun. Every time I pick up a car I'm always paranoid that everything is wrong with it. I guess that's because I am not yet familiar with the car. So I posted a thread when I thought it had a blown headgasket (http://zilvia.net/f/engine-tech/552059-advice-my-new-s13-ka24de.html). Bottom line, looks like the HG may be ok.

Anyway, car is a stock 1991 240sx automatic. Body is in decent shape, but needs some love. Motor seems to run ok, but I plan on swapping it out in the near future along with a manual transmission. I started doing some basic maintenance and cleaning on the car. First thing was new plugs, oil change, a seafoam treatment, a little washing, etc. Yesterday I started ripping out the interior. I wanted to check the blower motor because when I turned it on it made some god awful noise. This is why:
http://i264.photobucket.com/albums/ii166/jrusty15/20140131_144302_zpstpe1t6hf.jpg (http://s264.photobucket.com/user/jrusty15/media/20140131_144302_zpstpe1t6hf.jpg.html)
http://i264.photobucket.com/albums/ii166/jrusty15/20140131_144305_zps7wnjrtvp.jpg (http://s264.photobucket.com/user/jrusty15/media/20140131_144305_zps7wnjrtvp.jpg.html)

I cleaned it all out and now the blower doesn't make any funny noises. The car had been sitting for a while so there were lots of nests and shit everywhere. Once the interior was out I cleaned it all up. The trunk has a bit of surface rust which I plan to clean up. But what kind of worries me was the condition of the fuel pump area.
http://i264.photobucket.com/albums/ii166/jrusty15/20140131_121747_zpsh1zc1d3g.jpg (http://s264.photobucket.com/user/jrusty15/media/20140131_121747_zpsh1zc1d3g.jpg.html)
http://i264.photobucket.com/albums/ii166/jrusty15/20140131_121741_zpsp9yoqgmt.jpg (http://s264.photobucket.com/user/jrusty15/media/20140131_121741_zpsp9yoqgmt.jpg.html)
http://i264.photobucket.com/albums/ii166/jrusty15/20140131_121736_zpsgtitpbfc.jpg (http://s264.photobucket.com/user/jrusty15/media/20140131_121736_zpsgtitpbfc.jpg.html)

How bad is this? Will it be a huge problem when I go to put in a new fuel pump?

Anyway, the interior is mostly out. Some trim panels and the carpet still remain for now, but will come out soon. Here is how it sits:
http://i264.photobucket.com/albums/ii166/jrusty15/20140131_122204_zps0qsvsjcw.jpg (http://s264.photobucket.com/user/jrusty15/media/20140131_122204_zps0qsvsjcw.jpg.html)
http://i264.photobucket.com/albums/ii166/jrusty15/20140131_122154_zpsis774hsp.jpg (http://s264.photobucket.com/user/jrusty15/media/20140131_122154_zpsis774hsp.jpg.html)
http://i264.photobucket.com/albums/ii166/jrusty15/20140131_122139_zpstnwspptq.jpg (http://s264.photobucket.com/user/jrusty15/media/20140131_122139_zpstnwspptq.jpg.html)
http://i264.photobucket.com/albums/ii166/jrusty15/20140131_122133_zps4gnscapk.jpg (http://s264.photobucket.com/user/jrusty15/media/20140131_122133_zps4gnscapk.jpg.html)

Next up is to flush the cooling system and put in a new thermostat. I drained what I could at the bottom of the radiator and put in a new thermostat. I had to let it sit overnight for the RTV to cure. Next chance I get I will flush out the system and put in new coolant. The previous owner had the orange stuff in there. Once that's out I will put in the green stuff.

Next few items up on the list:
1) Replace brake master cylinder and bleed the brakes
2) New diff fluid
3) Get a valid inspection sticker. Luckily NJ only checks for emissions and gas cap. Since it's pre-1996, they just put the probe in the exhaust.

After that some of the bigger goals are to upgrade the suspension, put in a manual trans, and a motor swap. I'm not exactly sure what motor I'm going with, but I'm leaning towards an SR20. Mostly for the convenience, abundance of parts and online knowledge base, and price. However I'm also considering putting on a small turbo on the stock KA until it blows up until I get around to the motor swap.

[JRusty15]

Just a quick update. I started flushing out the cooling system. I must have filled it up 3 times and drained it and I'm still seeing orange coolant coming out. Unfortunately the temp gauge on the cluster still wouldn't work for me, so I didn't want the car running too long in case it was overheating. Also I wasn't getting any heat out of the vents, but that could also be air trapped in the system.

Then a few days later the new temp sensors (got both) came in and now the temp gauge on the cluster works. So hopefully this weekend I can pressure test the system and flush out all the orange coolant and bleed the system of air. Maybe even get some heat to come out of the vents!

[JRusty15]

I'm assuming nobody is reading this, but I will post another update anyway...

With a new sensor, the temp gauge in the cluster now works. It's funny though because it doesn't seem to go up slowly. It seems to just go from C to the middle when the car is warmed up. Anyway, I first filled it up with water to help flush out some more crud but I couldn't get the system to burp. Nothing came out of the "burp" plug as I call it by the temp sensors and I didn't see much if any bubbling from the rad cap opening. In addition, there was no hot air coming out of the vents with the heat blasting. So I drained what I could and filled it back up with coolant. Closed the burp plug and the rad cap and let it get to temps again. I revved the motor a bit, and at first there appeared to be some smoke coming from maybe the exhaust? It was hard to tell, but only happened once. I revved again and nothing. After revving, I noticed some black crud coming out of the exhaust. Some pics below. What do you think that could be? Oil? Maybe a leaky exhaust manifold gasket?

http://i264.photobucket.com/albums/ii166/jrusty15/20140208_133213_zpsabe1ab66.jpg (http://s264.photobucket.com/user/jrusty15/media/20140208_133213_zpsabe1ab66.jpg.html)
http://i264.photobucket.com/albums/ii166/jrusty15/20140208_133220_zpsc4ed2d35.jpg (http://s264.photobucket.com/user/jrusty15/media/20140208_133220_zpsc4ed2d35.jpg.html)
http://i264.photobucket.com/albums/ii166/jrusty15/20140208_133230_zpsc82cd774.jpg (http://s264.photobucket.com/user/jrusty15/media/20140208_133230_zpsc82cd774.jpg.html)

So I took the car for a drive and put some gas in it. It felt fine, the gauge didn't indicate it was overheating at all. Then while driving I turned the heat back on and I got hot air blowing out! Hooray! I'm guessing maybe the lines were clogged up or something? I'm going to take it to a shop to use the machine to flush out the cooling system.

I'm in the process of getting an Autometer water temp gauge working. I had one lying around from when I bought my evo. Looks like the gauge itself might need repair, but once that's working I will put that in the car to get a better idea of what the temps are doing. I'm suspecting the water pump may need to be replaced as well.

Once the car was back in the garage I installed a new brake master cylinder and a new fuel filter. Next time I'll bleed the lines at each wheel, and drain and fill the rear diff fluid.

[xoxide]

That's just built up carbon deposits/ water from hot exhaust touching cold air dripping out of your exhaust. Nothing to worry about

[JRusty15]

Phew! Thanks!

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[240sx707]

Digging it so far, More pictures! What's the outside of the car look like?

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[JRusty15]

66606 here is a quick picture of it in the garage. Ill post more up soon.

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[240sx707]

Looks like a decent project bud!

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[Javier13]

gl with your build!

[JRusty15]

I was going to drive it around today and get it inspected after I bled the brakes but unfortunately the brakes are worse than they used to be. When I bought the car the pedal was soft. I suspected the brake master cylinder. Replaced that and bled the system but now I have to pump the pedal even more to get the car to stop. I bled the brakes myself using tubing going into a bottle of fluid. Im wondering if there is just still air in the system? Any other thoughts?

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[Javier13]

bench bleed the master cylinder

[JRusty15]

I did. But I've never done it before so maybe I just didn't do it correctly?

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[Javier13]

if you feel like you're doing incorrectly refer to google or youtube.

[JRusty15]

I did. It didn't come with the tubes and adapters so I used my fingers. Thought I did it right.

Do I have to bleed the abs ?

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[JRusty15]

So I got to re-bleeding the brakes today. Did it in order according to the FSM. I used clear tubing in a bottle of fluid since I didn't have any helpers with me. Confirmed no air bubbles at each wheel and fluid is clean. Even got the ABS module bled successfully. However, when I drive the car, the pedal is STILL soft. It goes all the way to the floor before the car stops. I'm not sure what else it could be, but I'm starting to think the brake booster may be leaking air or something? Thoughts anyone?

[JRusty15]

I followed the steps in the manual to check the operation of the brake booster. See attached photo for steps. All tests passed. So what else could be bad? Could it just be a vacuum leak?

[JRusty15]

I started a new thread for the brake issue since it was more relevant: http://zilvia.net/f/showthread.php?p=5562799#post5562799

[FRESH2DEFCON]

Check your brake lines. May have busted. If not see if your calipers are leaking.

[JRusty15]

Nothing appears to be leaking, but I also haven't been able to check for seepage while applying the brakes. Tough to find a buddy to help with this cold/snowy weather.

[foreverdeath]

If its going to the floor cause of a leak, you will see a puddle some where. go back and rebleed those brakes. get your self a one-man bleeder kit try again.

[Redleader540]

If this is your first 240 you'll soon find out that most oem replacement parts are pretty cheap if you can find them either on here, or some other forum. Even if you can get decent condition junkyard parts, you wont be spending too much money until you start upgrading. Anyways, looking good so far, good luck man.

[FRESH2DEFCON]

Same thing happened to me but it was my brake master so lines is all I can suppose as you already replaced the BMC. Good luck man.

[JRusty15]

My mechanic buddy seems to think I just still have air in the lines somewhere...thoughts?

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[JRusty15]

I posted a thread about the brakes here: http://zilvia.net/f/showthread.php?t=555572

[JRusty15]

I finally got the brake issue sorted out. It appears the previous owner put the front calipers on the wrong wheels. This put the bleeder valve below the brake line and thus prevented me from ever getting all the air out of the system.

So moving on, I have a few more maintenance items to take care of before I can really get it on the road:

1) Outer tie rod ends
2) Fix exhaust leak (new cat-back)
3) Rear diff oil
4) New water pump
5) Diagnose why the speedo isn't working.
5) New shocks (rear's are completely blown).

I started off with the tie rod ends since they are simple. The process went pretty smoothly. Here are the old ones. Think they were bad?? Lol

http://i264.photobucket.com/albums/ii166/jrusty15/IMG_20140314_151235390_zpsnijgofqk.jpg (http://s264.photobucket.com/user/jrusty15/media/IMG_20140314_151235390_zpsnijgofqk.jpg.html)
http://i264.photobucket.com/albums/ii166/jrusty15/IMG_20140314_151227753_zpsuiztrolx.jpg (http://s264.photobucket.com/user/jrusty15/media/IMG_20140314_151227753_zpsuiztrolx.jpg.html)

Next I attempted to remove the old cat-back exhaust. Unfortunately the bolts connecting it to the cat were completely rust seized, so I rounded off the bolts. I'll have to cut them off next chance I get. Unfortunately I ran out of time, so next time when I get the exhaust out I can replace the gear oil and put the new cat back on. Then I'll get to the water pump. Then I can check the speed sensor and hopefully I'll get a new set of shocks or coilovers within the next week.

More to come. Slowly....but surely.

[JRusty15]

Got a chance to take another shot at the exhaust this weekend. The bolts on the catalytic converter studs were rust melted into one big round mess. Had to use a cut-off wheel and some patience to cut the bolts and part of the studs off to get the exhaust off the car. While it was off I managed to change the rear diff fluid. However trying to drill out the rest of the studs on the cat proved to be a pain. I didn't have any good drill bits on me and the battery on my drill was half dead. So I called it a day. I picked up a good set of cobalt drill bits from Sears which will hopefully help me drill out those studs. More to come.

[rangerjavi]

Glad to read that you sorted out the brake issue the good news is now you are master at bleeding brakes, lol should've just picked up some J30 or Q45 front calipers and rotors for an easy upgrade since you had to keep tinkering with the factory ones.

[JRusty15]

Thanks! I will get to upgrades a little later. Right now I just need to get the car a valid inspection sticker so I can legally drive it around.

[JRusty15]

Picture of the new exhaust versus the rusted out stock exhaust

http://i264.photobucket.com/albums/ii166/jrusty15/IMG_20140315_153040485_zpsmbgwpfae.jpg (http://s264.photobucket.com/user/jrusty15/media/IMG_20140315_153040485_zpsmbgwpfae.jpg.html)

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[mikey976]

nice build, your awfully close, my buddy is near you and has a white widebody s13.5 over in wharton, pm me I'm one of the few schassis in the area

i have a vh45 swapped hatch and building a built KAe-T coupe

[JRusty15]

Unfortunately this "build" so far has been slow and painful. After much blood sweat and tears, I finally go the new cat-back on the car. I took it to inspection again, same row, same machine, and I was told AGAIN that the sniffer couldn't get a reading. Do you guys think the machine is messed up? Or maybe my cat is clogged? I just need to get this turd on the road for now so I can finish up the repairs/mods to my evo.