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-   -   How to: 240sx Intake Swap (

JsD21HB 09-28-2008 03:43 AM

How to: 240sx Intake Swap
(Swap pertains to HB only) This is NOT for the ka24de found in frontiers. (dont have specifics if it is able to be done on a 95+ HB.)
I am finaly done with the 240sx intake install.
After getting lots of wrong info here is the stuff that is true.

What you will need:
240sx intake manifold and ALL sensors inculding MAF
Both 240sx and Truck wiring diagrams,vacumm diagrams, and pin voltage
12mm wrench
12mm socket and socket wrench
14mm socket
Soldering iron
About 4' 14awg wire
2' of 1/2" heater hose
2, 1/2" x 1/2" hose barbs
90* 2 1/2" peice of pipe
Flat plade screwdriver
About 4' of 3/8" heater hose(for the TB)
5/32" vacumm lhose
2' of 3/8" high pressure fuel hose
Asstorted hose clamps

Removing truck intake manifold:
1.) Remove all the intake shit
2.) Drain antifreeze
3.) Remove heater hoses from heater core.
4.) Start unpluging connectors for the Mass air flow, idle air control valve, Coolant temp,Air temp sensor,Injectors,and Crank shaft sensor or dizzy.
5.) Move half of harness out of way
6.) Remove upper radiator hose
7.) Disconnect Fuel lines
8.) Take out the 7 bolts and nuts that hold the manifold to the head.
Also remove the 2 lower mounting bolts.
9.) Either cut or remove the egr tube from the exhust manifold
10.) Remove the two bolts to the egr valve and remove it's vacumm hose
11.) There is a bolt holding the engine harness snugly to the manifold you are going to have
to remove that bolt as well
(A/T only remove the SCV contoll solenoid bracet from manifold in order to free kickdown
Should look something like this.
10.) Remove manifold without damaging the head(Prying with a screwdriver helped me.)

Installing 240sx intake

1.) Take your thourougly cleaned and egr blocked intake manifold and place it onto the head.
2.) Tighten the bolts in torque sequence.
3.) Install the 240sx injectors into the 240sx fuel rail and install rail on the manifold useing new
o-rings and seals with taking care not to rip them upon install.

4.) Cut Idle Air Controll valve harness of the truck before the IACV, FICD and connector.

5.) Solder the spare injector connectors to truck connector extend the leads about 18"s.

6.) After soldering connect the coresponding connectors to the IACV and the FICD. and hit ( Bang out the firewall in the corresponding location so the the two dont hit the firewall making it impossible to connect the ficd)
7.) Hook up heater hoses to TB and to the heater core.
8.) Crack P/S line loose and move it into position and tighent down out of the way of the manifold and
where intake pipeing is gonna be.
9.) Hook up intake piping and connect the MAF. I am pretty sure you can use the truck MAF if you
are carful and pay attention to how close the hot wires are to the inside of the case and use a washer
to space it out. But use the 240sx MAF it is a hell of alot easier.( When i first fitted the truck
MAF inside the 240sx housing I didn't realise that the hot wire extensions where touching the inside
of the case and grounding out.)
10.) Start pluging the injectors, MAF, IACV, TPS, SCV, and CPS in.
IMPORTANT: MAF PINS A=12v posititve (Black w/white) B=Ground (White) C=Signal (Black)
13.) Hook up electrical connection to the Air regulator with an
injector clip and run the wires to a KOER power source
(i.e. fuel pump relay like the 240sx wiring diagram specifies.)
12.) Hook heater hoses back up and the fuel lines back up.
13.) Route vacumm lines to the Carbon Canister and the FPR.
also if you left SCV then also hook up the vacumm solenoid
and vacumm canister.
14.) Drill 2 holes in the 90* bend and thread in the two hose barbs for the Valve cover vent and the IACV tubes.
(Make sure both are securely fastend with hose clamps dont want any vacumm leakes.)
15.) Fire it up. Your done. (you might have to adjust the idle screw.)

That is it.... If i doesn't run than you did something wrong....
P.M. me if you need help or just post a topic and i'll help.

slammed97 10-13-2008 04:53 PM

could u explain the sensor abreviations and where they are on the truck intake and the 240 totally lost on those...i have a motor that already has the intake swap done but im gonna have to do the plumbing and woring when i put the motor in the truck....

JsD21HB 10-14-2008 01:26 PM

it really needs to be redone but i fixed what i could pics are not really as good as they ought to be so please if u need specifics feel free to send a pm or post a ?.

thatboi_j 11-15-2008 10:55 PM

Can you e-mail me a better photo of where you had to beat in the firewall?

thatboi_j 11-15-2008 11:12 PM

Also what is the KOER power source?

JsD21HB 11-15-2008 11:16 PM

Key on engine Running or on what ever u wanna call it.

thatboi_j 11-15-2008 11:27 PM

where did you connect yours?

JsD21HB 11-15-2008 11:39 PM

i cant remember right off hand. but the fuel pump relay will work or u can also use the windshield wiper motor's power. or any other thing that is easily accesable and it could also be just a key on power source.

Asphalt Assassin 12-23-2008 02:24 AM

when you swap out the intake do you have to use the 240 injectores or will the old ones work also ?

JsD21HB 12-23-2008 01:08 PM


Originally Posted by Asphalt Assassin (Post 26245)
when you swap out the intake do you have to use the 240 injectores or will the old ones work also ?

ur stock hb injectors will work. for a short while there i was using 2 of my truck injectors and 2 240 injectors. seemed to run ok.

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