I know several of you out there have done KA24DE swaps and have had great success with them. I'm very close to getting mine done, but just need to install a new radiator, install the exhaust, figure out the air intake routing/components, resolve a steering/oil pan issue, wire it up and add fluids.
However, here are some of my issues that I'm hoping you guys might be able to help out with:
1 Radiator - the 3 row aluminum one I got from eBay doesn't have the mounting holes/tabs in the right position on each side of the rad, is a little bit taller than the original (but appears to be able to fit with the hood latched) and it doesn't have a drain bung and plug in the bottom. I got mine for Radiator Master through eBay, but I'm wondering if someone might happen to have a better resource or know of a radiator that will work without issue. I can't re-use the original, as most of the fins are rotted out or just plain gone.
2. Exhaust - the 4 into 1 header that I got may be too long and possibly too wide; we're thinking that if we cut down the length of the straight portion just before it collects into one that it might fit into the space between the engine and the steering column shaft, although I don't know that I want to start chopping up a brand new exhaust header on the "chance" that it will work. What have you guys managed to use to get things to work?
3. Air Intake - I got the MAF bracket from Redeye, that will allow me to mount the MAF over by the horns and the steering box, but I'm not sure what to use to route the intake from there over to the manifold. My buddy seems to think that it won't be too hard to figure out with either some silicone piping or maybe aluminum, but I'm just a bit concerned of the length and how to ensure it doesn't start to sag or anything. I'm guessing that without specific brackets or such, that most people just zip tie it to something to keep it somewhat stationary?
4. Oil Pan - I had gotten the Goferit tapered inserts that were originally mentioned as the way to go to flip the centerlink, and have managed to drill out the pittman arm and idler arm to be able to fit the tapers in, tack weld them in place and then tighten everything up. However, I am running into an issue where the passenger side outer tie rod end where it connects to the idler arm happens to make contact with the oil pan from the front sump pan of the 240SX KA24DE that I got. Redeye was suggesting that I just dent in the location with a ball peen hammer to provide clearance, but I wanted to see if anyone has come up with an alternative that may work better? I'll try and get pictures posted up of the contact location so that you see what I am talking about, but it's hitting right on the corner of the extension of the pan where the oil drain plug resides.
Thanks in advance for any help you can provide regarding these issues!