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Old 01-01-2008, 01:32 PM   #1
positron
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My S13 SR20DET Prep

Quick table of contents...could not put it on page 1 sorry!
*EDIT**********************************
I decided to put up a quick table of contents for those basic SR swap guys who just need a answer to that one question or just need to see that one pic to verify something.

PAGE 1------------------------------------------------
Introduction and engine breakdown(no pics).
Intake manifold breakdown
PAGE 2------------------------------------------------
Front oil seal replacement
Thermostat replacement
Engine paint
Engine cleaning
Aluminum steering bushing
Heater hose installation
PAGE 3------------------------------------------------
Engine bay painting
Powersteering pump problem #1 Click the image to open in full size.
Sidemount intercooler
PAGE 4------------------------------------------------
Water pump installation
Water pump aftermarket pulley installation
Upper and lower radiator hose install
Speed sensor swapout
Knock Sensor
Intake manifold gasket install
PAGE 5------------------------------------------------
CAS(Crank angel sensor) Replacement
Vacuum hose replacement
Turbo oil return hose install
Dipstick swapout Click the image to open in full size.
PAGE 6------------------------------------------------
Fuel injector seal replacement Click the image to open in full size.
Fuel regulator install
Oil filter sandwich plate...YOU FAILED EBAY!!!! Click the image to open in full size.
PAGE 7---------------------------------------------
Coolant temp sensor replacement
Coolant gauge sensor replacement
Alternator aftermarket pulley install
Vacuum hose install(intake manifold)
Fuel injector seal replacement cont.
Fuel rail install
CAS cover swapout
PAGE 8--------------------------------------------
Turbo breakdown OEM T-25
Turbo gasket install
PAGE 9--------------------------------------------
Water outlet/neck gasket install
Bolt/nut replacement with part #'s
PAGE 10------------------------------------------
Altima fans vs. Permacool???
Altima fan modifications(get a dremel!!!!) Click the image to open in full size.
Altima fan breakdown
Spark plug replacement
PAGE 11------------------------------------------
Altima fan modification cont.
Altima fan mounting to Koyo rad
Clutch pivot ball problem
Transmission dust collar replacement
Transmission slave cylinder replacement
Wire harness clips part#
Transmission gasket replacement
Power steering pump problem #2 Click the image to open in full size.
PAGE 12---------------------------------------------
Transmission gasket replacement cont.
Transmission rear seal
Transmission mount install
Clutch pivot ball install
Clutch pivot fork
Turbo stainless steel line install
Transmission drain plug install
Motor/Engine mount install
Turbo lines install cont.
Turbo manifold/outlet install
Turbo locking nuts install
Turbo manifold gaskets install
PAGE 13------------------------------------------
Rocker arm install
Transmission insulator mount install
Fuel line replacement
Greddy oil pan install
Oil strainer replacement
DiF Fan controller wiring Click the image to open in full size.
Valvecover install
Valvecover gaskets install
PAGE 14------------------------------------------
Clutch (no install)
Turbo outlet/outlet studs install
Flywheel (no install)
PAGE 15------------------------------------------
DiF fan controller wiring cont.
Hotpipe/B.O.V. (no install)
Oil filter relocation kit install
Clutch....again?!!!!
Power steering pump aftermarket pulley install
Power steering pump install problem #3 Click the image to open in full size.
Valvecover install cont.
O2 sensor install
PAGE 16--------------------------------------------
Boost controller (no install)
Wire harness (no install)
Power steering pump problem SOLVED!!! Click the image to open in full size.
Ignition grounding plate install
Water temp gauge install
Coolant/water line replacement under intake manifold
Water temp gauge cont.
Clutch line (no install)
PAGE 17--------------------------------------------
Gauge wiring for Boost/Oil pressure/Water temp
Engine install (no pics)
Steel braided Valvecover T lines install
PAGE 18--------------------------------------------
Intake filter & MAF install
Altima fan fitment modification cont. Click the image to open in full size.
Downpipe (no install)
Heater hose problem encountered and fixed!
PAGE 19--------------------------------------------
DiF fan controller problem #1
PAGE 21--------------------------------------------
Snap ring problems
Radiator feet part #
DiF fan controller problem FIXED!!!! Click the image to open in full size.
****************************************


I bit the bullet and finally decided to get a engine and attempt the SR swap. A couple of months ago me and three other people, who all have much more automotive mechanical ability than I do, pulled a KA from a hatch and got rid of it and pulled another KA from a coupe and swapped that into the hatch during a weekend. Participating in this swap was very useful in helping me to remove my KA and the knowledge that I got will be useful in helping me to perform my SR swap as well. After reading other peoples build threads I don't think I can call mine a "build" because I'm just shooting for the bare-bones basic SR swap. I plan to swap out as many gaskets as I can, the front/rear main oil seals, waterpump, thermostat, spark plugs and possibly add a few aftermarket parts over their stock counterparts. If somebody sees something that I am doing wrong by all means chime in because I need all the help I can get.

!!!!ADDED A QUICK TABLE OF CONTENTS FOR THOSE WHO DON'T WANT TO WASTE TIME SEARCHING THE ENTIRE THREAD FOR THAT ONE PIC OR ANSWER TO A QUESTION...IT'S ON PAGE 24...COULDN'T PUT IT ON THE FIRST PAGE SORRY!!!!!!

Click the image to open in full size.
I got my engine in from JSA Motors. Everything was intact, no missing pieces or parts(MAF/Ignitor chip), no broken crank angle sensor and a complete uncut wiring harness. Shipping was swift and I was able to track it to my delivery point. My only complaint was that the block was a little grimey, they said they would clean it before strapping it to the skid.Click the image to open in full size.
Click the image to open in full size.
S13 Redtop SR20DET
Click the image to open in full size.
The transmission is intact and very clean...
Click the image to open in full size.
no transmission crossmember but I can use my KA's crossmember.
Click the image to open in full size.
First thing I did was bust open the valve cover and inspect the internals, during my research I read some horror stories about people getting engines with rust and dirt inside.Click the image to open in full size. Apparently someone wasn't too fond of oil changes.
Click the image to open in full size.
After that I completely broke down the exhaust side of the block. Striped everything!
Click the image to open in full size.
Did the same for the intake side.
Click the image to open in full size.
I removed the alternator, P/S pump, A/C compressor and the belt driven fan.
Click the image to open in full size.
Broke out the bucket O' water, scrub brushes and Mean Green and started scrubbing away but I got tired of killing my back working on this engine on that old tire....
Click the image to open in full size.
and borrowed a buds engine stand. This thing is a life saver!!!!!!
Click the image to open in full size.
Look at all the stuff I pulled, hope I can remember where everything goes when I try to put it back.
Click the image to open in full size.
After cleaning every knookie and cranny on this block I taped off everything I didn't want to get coated and laid down a couple of coats of high heat iron cast aluminum engine enamel to the block.
Click the image to open in full size.
Turned out better that I thought it would.
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S13 Power Folding Mirror Install http://www.s-chassis.com/forums/showthread.php?t=39469
S13 KA24DE Engine Removal http://www.s-chassis.com/forums/showthread.php?t=42397
S13 SR20DET Prep http://www.s-chassis.com/forums/showthread.php?t=42547

Last edited by Biggamehit; 06-17-2009 at 08:40 AM.
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Old 01-01-2008, 06:53 PM   #2
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How come you didnt mask off the valve cover when you painted the engine? Gonna powder coat it or something?
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Old 01-01-2008, 07:01 PM   #3
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yea thats the only thing that didn't look good. im sure hes going to get a new gasket tho.
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Old 01-01-2008, 08:15 PM   #4
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god....i wish my swap was like that


it was dirty as **** and the harness was ****ed

no maf

no igniter

bull****....

looks good...re powder coat that valve cover and it'll be sex
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Old 01-02-2008, 04:57 AM   #5
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Yeah, I'm gonna powdercoat the valve cover but I should have taped it off anyway, just got lazy and impatient.


Now that I had everything cleaned up I turned my attention towards replacing parts. The first parts that I attempted to swap out were the main oil seals. I read up on what should be changed out on any basic engine swap and the oil seals were at the top of the list among other things such as oil pump, water pump, thermostat, spark plugs, various gaskets, motormounts, oil pan, etc.

FRONT OIL SEAL REPLACEMENT

Tools needed:
Socket wrench
Socket extension
27mm socket
Chain
1 transmission bolt
2 flywheel bolts
Pulley puller
Breaker bar
Seal puller or prybar/screwdriver
Seal driver

I want to change out the front and rear main seals but I can't get to the rear with the engine on the stand but the front is accesible. To get to it you need to remove the crank pulley but I couldn't get the pulley bolt off because the crank kept spinning when I tried to man up on it and I don't have any air tools so I had to think of another way. I decided to use the chain and the links that I used to pull my KA to help me.
Click the image to open in full size.
I put two flywheel bolts through the chain and threaded them into the crank.
Click the image to open in full size.

Click the image to open in full size.

Click the image to open in full size.
I looped the chain around the engine stand, stuck a transmission bolt into the link and threaded that into the transmission housing.
Click the image to open in full size.
This kept the pulley from spinning.
Click the image to open in full size.
This allowed me to use my 27mm socket and breaker bar to bust the crank pulley bolt loose.
Click the image to open in full size.

Click the image to open in full size.
Now I just need to get a pulley puller from the parts store to pop it off so I can replace the front main seal.
Click the image to open in full size.
Here, you can see the rear main seal that I can't get to yet. Anyone know how it comes out? Does it pry out with a screwdriver or something?
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S13 300ZX Rear Brake Install http://www.s-chassis.com/forums/showthread.php?t=41156
S13 Subframe Collar Install http://www.s-chassis.com/forums/showthread.php?t=38437
S13 Power Folding Mirror Install http://www.s-chassis.com/forums/showthread.php?t=39469
S13 KA24DE Engine Removal http://www.s-chassis.com/forums/showthread.php?t=42397
S13 SR20DET Prep http://www.s-chassis.com/forums/showthread.php?t=42547

Last edited by Biggamehit; 06-17-2009 at 08:41 AM.
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Old 01-03-2008, 05:58 AM   #6
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for the exhaust manifold gasket. use an 02 sentra with an sr20. that is the best exhaust manifold gasket you can get.

use lock washers on the exhaust manifold also to make sure it's sealed properly.

carquest sells heater hoses that work perfectly for $20 to route your heater core piping. if i can find the part #s i'll post them up.

part# from car quest to get the heater hoses:

19628
19619

Thank durdan on the forum for the info.
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Old 01-03-2008, 01:19 PM   #7
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Man that is very clean
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Old 01-04-2008, 06:27 AM   #8
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Quote:
Originally Posted by Bumnah View Post
for the exhaust manifold gasket. use an 02 sentra with an sr20. that is the best exhaust manifold gasket you can get.

use lock washers on the exhaust manifold also to make sure it's sealed properly.

carquest sells heater hoses that work perfectly for $20 to route your heater core piping. if i can find the part #s i'll post them up.

part# from car quest to get the heater hoses:

19628
19619

Thank durdan on the forum for the info.
Thanks but I already have a set of heater hoses and an exhaust manifold gasket as well. I will get the lock washers as you suggested. Quick question though, since I plan to stay stock I wouldn't see any benefits from upgrading the intake manifold from the OEM manifold to an aftermarket manifold would I?
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S13 300ZX Rear Brake Install http://www.s-chassis.com/forums/showthread.php?t=41156
S13 Subframe Collar Install http://www.s-chassis.com/forums/showthread.php?t=38437
S13 Power Folding Mirror Install http://www.s-chassis.com/forums/showthread.php?t=39469
S13 KA24DE Engine Removal http://www.s-chassis.com/forums/showthread.php?t=42397
S13 SR20DET Prep http://www.s-chassis.com/forums/showthread.php?t=42547
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Old 01-04-2008, 01:35 PM   #9
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OEM Intake Manifold

Click the image to open in full size.
Today I took my intake manifold apart and cleaned it up. I'm gonna replace the gaskets and maybe the IACV as well.
Click the image to open in full size.
Broke it down, intake runners, intake collector, IACV(idle air control valve) and the throttlebody.
Click the image to open in full size.
The first thing I did was clean up the throttlebody...
Click the image to open in full size.
It was pretty dirty.
Click the image to open in full size.
Cleaned.
Click the image to open in full size.
I'll replace the throttlebody gasket when I put the intake manifold back together.
Click the image to open in full size.
The intake collector was full of carbon buildup.
Click the image to open in full size.
I got some brushes and cleaned it out pretty good too. I'll replace the intake collector gasket as well.
Click the image to open in full size.
The IACV.
Click the image to open in full size.
I can't decide whether or not to clean this up or just replace it. I came across a write-up on how to clean one but I can't find it again.
Click the image to open in full size.
Carbon build-up.
Click the image to open in full size.
Got some new hoses to replace the ones on the intake manifold.
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S13 300ZX Rear Brake Install http://www.s-chassis.com/forums/showthread.php?t=41156
S13 Subframe Collar Install http://www.s-chassis.com/forums/showthread.php?t=38437
S13 Power Folding Mirror Install http://www.s-chassis.com/forums/showthread.php?t=39469
S13 KA24DE Engine Removal http://www.s-chassis.com/forums/showthread.php?t=42397
S13 SR20DET Prep http://www.s-chassis.com/forums/showthread.php?t=42547

Last edited by positron; 05-13-2008 at 09:40 AM.
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Old 01-04-2008, 02:11 PM   #10
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i'd stick with oem. until you're really need something more. the more factory parts in a motor the better it runs. the intake manifold won't make any huge difference. i hear the greddy manifold gives more mid rang power by sacrificing a little on the low end. i don't know how accurate that is, since it's internet information, and as far as i'm concerned it's right 30% of the time.

You're doing a great job on this prep. I did some of the stuff you're doing. I didn't take off the manifold and take it apart though. My only concern would be putting it back together, and not having any air leaks. all those places would be a place you have to check to find vacuum leaks if you have any once it starts running. I understand why you did it, I'd probably go the same route, just make sure you torque it down properly. I did clean up tons of bolts during my prep, and I never forced anything down.

The heater hoses I listed for $20 are the ones Enjuku sells for $40. I hope you didn't get a copper exhaust manifold gasket, if so get the oem I listed. All information passed onto me when I did my sr swap. Now would be a great time to drill that exhaust manifold for an EGT gauge or wide band o2

My sig should have a link to pix for my swap.
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Old 01-04-2008, 11:24 PM   #11
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Could you use a little RTV or something when you put it back together?
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Old 01-05-2008, 12:02 AM   #12
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whats wrong with the copper gasket??

i was told that they are like 50 times better by atleast 3 of my friends...

are they bad?? i haven't ordered the **** yet so...
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Old 01-05-2008, 12:07 AM   #13
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i've heard they blow. get the one i listed it's the best. half the price as well

Quote:
Originally Posted by ryguy View Post
Could you use a little RTV or something when you put it back together?
rtv could work. i'd probably just use new gaskets. if they weren't found then use rtv.
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Old 01-05-2008, 12:24 AM   #14
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you mean the one of the SR Sentra??

thanks man
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Old 01-05-2008, 09:49 AM   #15
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I checked out Project Eva, excellent pictures of Bumnah's swap, also very useful. I saw some things I haven't seen before.
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S13 300ZX Rear Brake Install http://www.s-chassis.com/forums/showthread.php?t=41156
S13 Subframe Collar Install http://www.s-chassis.com/forums/showthread.php?t=38437
S13 Power Folding Mirror Install http://www.s-chassis.com/forums/showthread.php?t=39469
S13 KA24DE Engine Removal http://www.s-chassis.com/forums/showthread.php?t=42397
S13 SR20DET Prep http://www.s-chassis.com/forums/showthread.php?t=42547
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