How to 95-KA-wiring.pdf

I'll have updates of my own shortly...

I also had them swap out the 280ZX mechanical speed sensor (It was leaking and didn't work) with a first gen 300ZX mechanical speed sensor and now my stock 510 speedo is working. (Although I think I need a new cable... kinda jumpy at slow speeds)

I pulled the rear springs out this weekend and cut a coil off of them in order to get some negative camber out of the penultimate crossmember. (Moved the pivot points up so the springs were now too tall.) I think I got the alignment as close as I can... now I just need to take it in and have all four corners aligned. Otherwise the car drives really nice. Been starting to push it a little harder now and I'm amazed at the power this engine has! (And the fans finally kicked in for the first time while I was waiting at a stop light... Nice to know that they work beyond me shorting out the temp sensor on the radiator. :)

I also installed a billet pedal and noticed that I need to do something about how close the accelerator is to the brake pedal. Thought this was odd until I looked at my wagon and noticed that the accelerator and brake pedals are much father apart then my two door. Turns out since my two-door was a former automatic, the rod is a different shape... I guess I'll bend it to match the wagon's accelerator linkage. The To-Do list is now the following (In more or less order that I'm going to do it in):

• Alignment. (Penultimate in the rear... camberplates in the front.)
• Install some aux gauges (oil pressure, water temp, etc.)
• Fabricate something to box up the area around the new shifter hole so I can mount a shift boot.
• Install some new carpet into the front half of the interior.

Here's what has been done since the last update:

• Replaced the leaking brake line with a NOS one I got from Randy York.
• Installed Cusco camberplates, TechnoToyTuning camber plate top-hat and one of there strut bars and finally had a proper set of perches welded on my struts for the threaded collars to sit on. (Was using a clamp, but interfered with the tires/rim.)
• Cleaned up some of the excess KA wiring from the engine compartment.
• Wired up the fuel pump to be triggered by the ECU. (Formally was triggered off of accessory power)

• Fix the clutch issue. (I think the clutch disc is stuck to the flywheel) Car is at my mechanic this week to pull the tranny... (pulling the tranny wasn't high on my "really want to do" list.)
• Fabricate something to box up the area around the new shifter hole so I can mount a shift boot.
• Install some new carpet into the front half of the interior.
• Alignment. (Penultimate in the rear... camberplates in the front.)

This past weekend I managed to pick up a really cheap ram-air intake pipe for a 240SX and cut out a 4" section to make it fit. It's not pretty, but it's only temporary until I can get a pipe fabricated.

The to-do list has now been shortened down to:

• Finish routing the wiring and eliminate the un-needed sections of the KA harness.
• replace the brake line feeding the rear brakes. My re-flaring and union of the cut line is leaking, so I'm going to rip it out and put in a new line.
• First test drive (Beyond the garage and driveway) and work out all the kinks.

• Finally got a fan belt that fits the waterpump and crank. This is a temporary solution until I get an idler pulley set-up.
• Ended up taking out all of the Earl superblue fuel lines and AN fittings out. I couldn't get the fittings on properly after repeated attempts so I decided to get some lines made for me. (Thanks to the guys at Dave Turner Motorsports!)
• Had to purchase a new 300zx fuel pump... The one I bought at the junkyard took a dump and I just didn't have the time or desired to go stomping thru the yard looking for another one.
• Modified the stock accellerator linkage to accept the 240SX throttle cable. Had a local shop cut and swap the tips from the 240SX and 510 accellerator linkages. Had to rebend the 510 linkage a bit to allow for full operation.
• Fabricated a simple mount so I could mount the ECU to the passenger kickpanel. I'll fabricate a cover and modify the stock kickpanel cover once the car is running.

• Wiring the ECU.
• finish wiring the fuel pump relay to be controlled by the ECU.
• Finish the electric fan wiring.
• Fabricate a temporary intake tube so I can mount the AFM/air filter.

• Have the starter, alternator and oil wiring connections completed. Filled the motor up with some fresh oil and took it for some test spins :)
• Exhaust system is in. I went with a 2.25-inch aluminized system, including a resonator and a stainless "Bullett" brand muffler and tip. (The guys at Express Muffler and Hitch did an awesome job!)

I was a bit shocked at the Nissan pricing on their O2 sensors ($175!) so I purchased an aftermarket Bosch unit. Still looking for a suitable lower radiator hose... I'll use a generic flexable hose temporarily if need be.

Hit the junkyards this weekend searching the other late-model Nissans for any possible bolt-on solutions for the idler-pulley... nothing popped-up so I think I'm going to have to home brew by own solution.

I finally also got my hands on a modified KA exhaust manifold. (O2 sensor bung relocated -- pictures below.) Just need to make a trip to the local autoparts store to pickup some gaskets and I should be just about ready for a trip to the exhaust shop...

I've gotten quite a few e-mails from folks. Thanks to everyone who has given me advice/tips! I haven't gotten back to everyone at this point, but I will. One of the bigest questions I get is how to wire up the engine harness and ECU to the 510... I still haven't done this step, but I'm getting real close. Below you will find a few 240SX wiring diagrams in PDF format, enjoy!

system wiring diagrams

This one contains the whole 240sx wiring diagrams... a bit overkill.

wiring diagrams

Engine related wiring diagrams.

Progress over the last few months has slowed up a bit as I've run into a few roadblocks:

Still have tons of stuff to do before it will run. Here's a quick run down of what's left to do:

Late June 2002 - Installed the new fuel supply/return lines and the custom radiator. (VW VR6 aluminum radiator with some customizations to move the inlet and outlet holes and add a radiator cap.)

Picked up my new fuel supply/return lines from TSR fabrication and dropped off my fuel tank to get a 300ZX in-tank fuel pump installed. The radiator is almost done, just needed to weld in the new inlet/outlet fittings. (Should have that by next weekend.)

Have been working on resolving a lot of the little things on my list. I'll have more pictures up soon. Here is what I've done the few past weeks:

• I replaced the electronic speed sensor (remember most vehicles don't use mechanical sensors anymore) on the KA tranny with one from 280ZX.
• Installed an automatic 510 speedo cable (longer than the manuals) to reach the KA's speed sensor.
• Removed the fuel tank.
• ripped out the stock fuel supply line and fuel vapor line.
• Installed offset brackets on the penultimate crossmember so my tires will clear the fenders.

Rear Calipers are installed. Still need to run new brake lines to them. Driveshaft is finally re-installed after waiting a few weeks for the new bolts to get in from Nissan. (Old ones looked like crap and I figured I might as well put new ones in since I'll be running considerably more power...)

Got my shorten driveshaft back... But this got me to thinking that now would be a good time to install that Penultimate crossmember that has been sitting in the garage for nine months. (Since I was going to have to rip the exhaust off anyways... ) While the trailing arms were off I decided to drop them off at a machine shop to get the drum brake backing plates (say that ten times!) off so I can swap over to rear discs.

Jan 2002 - Started working on finishing up the modifications to the transmission tunnel so the KA tranny (and specifically the raised box around the shifter) will clear and not rub. (The GM tranny mount requires a 7/16" course grade bolt to mount it to the tranny crossmember. Found the correct sized bolt at my friendly commercial/industrial hardware store.)