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glacier985
Dont Question My Nissan Knowledge
Joined: 27 Apr 2005
Posts: 500
Location: Hebron, Oh
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 Posted: Mon Mar 20, 2006 7:59 am Post subject: DIY Emissions Removal SOHC |
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Ka24e DIY Emissions Removal
1. Stock Intake
-- a. Emissions Parts
---- i. Location
2. Other Emissions Parts
-- a. Location
3. Vacuum lines
4. What to keep and remove
5. Going a Step Further
6. Disclaimer
Tired of looking at that stock intake and wondering what you can do to clean it up? Maybe add some power while you’re at it to? Well let’s take a look at what we can remove.
Here is a diagram from the FSM of the engine and emissions control devices. They are numbered for easy reading.
Stock intake
1. EGR control valve, this controls the quantity of exhaust gas that is let into the intake manifold. It is located on the back of the intake and has a metal tube that goes to the exhaust manifold. This can be removed and no codes should be thrown and no check engine light. If not a 100K ohm, 1/4 watt resistor in place of the EGR temp sensor in its place to fix it.
2. BPT valve, this monitors the exhaust pressure to activate a diaphragm that controls the EGR vacuum. It is located on the back and inside of the plenum and is on top. Really easy to spot. Remove it and no code will be thrown.
3. FPR, this is on the back of the fuel rail and is necessary for the engine to run properly. DO NOT remove it.
4. Pressure regulator control solenoid valve and SCV control solenoid valve. These are located on the back of the head, along with a bundle of hard lines and vacuum hoses. Remove them and that’s it, no codes.
4a. SCV actuator (not pictured), since the SCV solenoid was remove, this must be removed. This is located on the back of the intake manifold. It’s on the right side and controls the butterflies. Once it is removed you can do away with them as well. Each one is held in by two screws. Remove all four plates, the small screw in the middle of the intake and then pull the rod out. You can either have the rod holes welded shut or use JB weld.
5. Air regulator, located on the inside of the intake plenum, basically helps the car warm up when it’s cold. I kept this and if you drive your car in the winter or start it when it is cold you should do the same. Warmer climates probably don’t need this.
6. EGR Control Solenoid, toward the front on the left side and bottom of the intake. EGR is gone, so remove it.
7. IAA unit includes the ACC valve. This is located on the back of the intake plenum and controls the idle of the motor. Its one of the few things I kept and I believe is necessary for a good running, street-able engine.
Other Emission Parts
8. AIV case and control solenoid. It’s the big ugly mess on the drivers side strut mount. You’ve probably got rid of it already, but if not, go ahead and throw it in the trash, but be sure to plug the hole in the exhaust or the metal hose.
9. Charcoal canister, big black cylinder on the driver’s side front of the engine bay. Remove, the vacuum lines come later.
Vacuum Lines
After the removal of all the emissions comes the question of vacuum lines. On my current NA setup I have two vacuum lines, both maybe 2 inches long. How did I do this? Easy, if you have the same setup as me every vacuum line can be removed, except for two. The bundle of hard lines that run down the middle of the intake can be removed and the lines that run to the charcoal canister can go to. I went as far as even removing a hard line that runs from the transmission tunnel to the charcoal canister. It’s the fuel tank vent and the hose needs to be left unplugged.
Now what lines to keep? The FPR will now be the only thing that needs a vacuum source. All I did was run a line from the intake hard line to the hard line on the fuel rail and then a line from that to the FPR.
What to Keep and Remove
Keep
i. Air Regulator
ii. AAC unit
iii. FPR
Remove
iv. EGR
v. BPT valve
vi. PR and SCV solenoid
vii. SCV actuator and butterflies
viii. EGR control solenoid
ix. AIV case
x. Charcoal Canister
Things Kept
Going a Step Further
Want to go the extra mile for the clean look? Here’s a few tips on what to do.
• Extend the injector plug wires and other harness plugs and run the wiring harness under the intake.
• Grind off the BPT valve tabs (pictured)
• Remove coolant lines running on plenum and grind off hard lines and block left after removal. (pictured)
• Remove vacuum source on the left side of plenum
• Grind off ECCS
• Paint Cast-Coat Aluminum for a nice finish
Disclaimer
- I am not responsible for any harm done to your engine by following this guide to removing emissions. I’ve had no problems in the year I have had them removed. If you live in an area with emissions testing I suggest you do not remove anything. Any questions and/or concerns can be sent through a PM or email.
All text and images Copyright Justin Glaser 2006
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1990 240sx SE, 96K, ka24eT [b]Upgrade Time
Last edited by glacier985 on Sun Jan 07, 2007 9:12 pm; edited 3 times in total |
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P4rD0nM3
Hella Old School
Joined: 31 Aug 2005
Posts: 603
Location: Grand Junction, CO
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| Posted: Mon Mar 20, 2006 9:33 am Post subject: |
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Hmm, looks like I forgot some stuff to take out. Goodx stuff bro good ****...thanks.
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JP
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Joined: 30 Nov 2004
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| Posted: Wed Mar 22, 2006 6:51 am Post subject: harness |
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| what did you do with the wiring harness connections |
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glacier985
Dont Question My Nissan Knowledge
Joined: 27 Apr 2005
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Location: Hebron, Oh
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| Posted: Wed Mar 22, 2006 7:07 am Post subject: Re: harness |
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| JP wrote: | | what did you do with the wiring harness connections |
I extended the plugs, by cutting them and soldering new longer piece of wire between the harness and the plug. I then ran the wiring harness under intake manifold. I think I needed to extend all four fuel fuel injectors, the two grounds that bolt on the head, coolant temp sensor connector, and the ground beside it. Everything else was long enough. I can get soe pictures for you if you'd like.
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nis720
Knows Some Stuff About 240's!
Joined: 23 Mar 2006
Posts: 320
Location: Compton, CA
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| Posted: Thu Mar 23, 2006 2:58 pm Post subject: |
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Do you have an overall shot of the intake?
Good info...... specially now that I'm preping my intake.
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glacier985
Dont Question My Nissan Knowledge
Joined: 27 Apr 2005
Posts: 500
Location: Hebron, Oh
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| Posted: Thu Mar 23, 2006 6:44 pm Post subject: |
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| nis720 wrote: | Do you have an overall shot of the intake?
Good info...... specially now that I'm preping my intake. |
No, but I will have one tomorrow when I actually get home from work when it is still light outside.
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morodo_s13
Knows Some Stuff About 240's!
Joined: 24 Mar 2006
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| Posted: Sun Mar 26, 2006 10:03 pm Post subject: |
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nice writeup,
do you have pictures of how clean yours looks? |
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glacier985
Dont Question My Nissan Knowledge
Joined: 27 Apr 2005
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Location: Hebron, Oh
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| Posted: Tue Mar 28, 2006 7:40 pm Post subject: |
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Finally rembered to get some pictures......
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silviasxy
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Joined: 02 May 2005
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Location: Woodcock, GA
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| Posted: Tue Mar 28, 2006 8:28 pm Post subject: |
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Good write-up...everything should be good for a turbo too right? And what is running over your valve cover? 
Looks good though!! 
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- Brit
'89 240sx coupe - Silvia/KA24ET project |
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morodo_s13
Knows Some Stuff About 240's!
Joined: 24 Mar 2006
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| Posted: Tue Mar 28, 2006 8:36 pm Post subject: |
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silvia, that line is the turbo oil feed line, and that car has a turbo,
lol, glacier if i print several of your engine bay pics i can puzzle up how your engine bay looks lol  |
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silviasxy
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Joined: 02 May 2005
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Location: Woodcock, GA
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| Posted: Tue Mar 28, 2006 8:55 pm Post subject: |
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My bad, I haven't ever seen the oil line run over the valve cover.
And that answers my other question too! 
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'89 240sx coupe - Silvia/KA24ET project |
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glacier985
Dont Question My Nissan Knowledge
Joined: 27 Apr 2005
Posts: 500
Location: Hebron, Oh
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| Posted: Tue Mar 28, 2006 8:56 pm Post subject: |
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| morodo_s13 wrote: | silvia, that line is the turbo oil feed line, and that car has a turbo,
lol, glacier if i print several of your engine bay pics i can puzzle up how your engine bay looks lol |
I'll have some full engine bay pictures up soon, just waiting on the right size t-bolt clamps.
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nis720
Knows Some Stuff About 240's!
Joined: 23 Mar 2006
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Location: Compton, CA
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| Posted: Mon Apr 03, 2006 6:47 pm Post subject: |
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When you removed coolant hard lines running on the upper plenum did you have to weld something?
I started grinding on mine and soon noticed there's a cavity in the center and now have a hole in my intake. I'm going to have to get it welded before I take it to get polished.
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nis720
Knows Some Stuff About 240's!
Joined: 23 Mar 2006
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| Posted: Mon Apr 03, 2006 7:39 pm Post subject: |
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Here's a pic of my intake..... Some welding and reinforcing will fix it.
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samurai808
NooB
Joined: 04 Apr 2006
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| Posted: Tue Apr 04, 2006 1:47 am Post subject: |
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Hey, ive been watching/ learning on these boards for a while now but i have a question for you guys modding the plenum... i just gotta tell ya that it look slike some good work, look snice and clean!!! other than that, i just wanted to know if the coolant lines on the side of the plenum and the front of the throttle body have any actual use? lol i wanted to just re route the coolant line from the bottom side pipe to the little pipe coming out of the manifold radiator thing but i wasnt sure if that would affect anything.
if ya could lemme know how safe it is to do away with the lines going to the plenum and throttlebody that would be fantabular lol thx =P
btw, thx for the writeup, really cleared things up for me! |
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glacier985
Dont Question My Nissan Knowledge
Joined: 27 Apr 2005
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Location: Hebron, Oh
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| Posted: Tue Apr 04, 2006 7:27 am Post subject: |
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Yea I had to get mine welded closed, I also got rid of a vac hardline on the plenum. The one right up next to the throttle body.
Samurai, those coolant lines are referred to as the "coolant bypass". There suppose to heat the air coming into the intake to help warm up the motor I think. I just removed the lines and connected a hose from the small hardline coming from the intake coolant connection and then it goes to the small hardline that comes out of the hardline that runs under the manifold to the heater core. It's hard to get pictures, but I have a couple spare manifolds that I can show you pictures if you need them.
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nis720
Knows Some Stuff About 240's!
Joined: 23 Mar 2006
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Location: Compton, CA
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| Posted: Tue Apr 04, 2006 7:57 am Post subject: |
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| glacier985 wrote: | Yea I had to get mine welded closed, I also got rid of a vac hardline on the plenum. The one right up next to the throttle body.
Samurai, those coolant lines are referred to as the "coolant bypass". There suppose to heat the air coming into the intake to help warm up the motor I think. I just removed the lines and connected a hose from the small hardline coming from the intake coolant connection and then it goes to the small hardline that comes out of the hardline that runs under the manifold to the heater core. It's hard to get pictures, but I have a couple spare manifolds that I can show you pictures if you need them. |
Ok... I thought I messed up.... I'll have to find someone that can weld it shut..... I decided to get it looking like yours, I removed the rest of it and now I just need to have the gapping hole covered.
Did you weld it yourself?
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glacier985
Dont Question My Nissan Knowledge
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| Posted: Tue Apr 04, 2006 4:28 pm Post subject: |
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| nis720 wrote: |
Did you weld it yourself?
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no, i don't know how to TIG yet, but I plan on learning in a year. I had my uncle do it, he also did the inlet and outlets on my intercooler.
BUt thats exactly what my hole looked like, if I was you I would remove the two tabs on the back of the plenum, unless you plan on keeping the BPT valve.
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nis720
Knows Some Stuff About 240's!
Joined: 23 Mar 2006
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| Posted: Wed Apr 05, 2006 10:38 pm Post subject: |
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I plan to keep some emissions stuff (Cali smogging) so I'm keeping the BPT tabs.
$40 later the hole is filled.
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P4rD0nM3
Hella Old School
Joined: 31 Aug 2005
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Location: Grand Junction, CO
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| Posted: Thu Apr 06, 2006 6:33 pm Post subject: |
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Can I ask the whole engine bay pic Mr. Glacier? For reference purposes...
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glacier985
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| Posted: Thu Apr 06, 2006 6:38 pm Post subject: |
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| P4rD0nM3 wrote: | | Can I ask the whole engine bay pic Mr. Glacier? For reference purposes... |
Hi-res? I'll get it tomorrow, 3.1 MegaPixels is the biggest I can get. Any other pictures just ask.
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P4rD0nM3
Hella Old School
Joined: 31 Aug 2005
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| Posted: Thu Apr 06, 2006 9:17 pm Post subject: |
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OK i'll ask thru PM. Bec, I dunno those seal thingies and vaccum lines...
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slayton
Dreams of owning a 240!
Joined: 12 Apr 2006
Posts: 66
Location: regina saskatchewan
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| Posted: Wed Apr 12, 2006 8:33 pm Post subject: |
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so is there any way to remove everything exept for the secondary controlers, fpr, iaa, and air regulator without having any any engine codes coming up?? instrustions??
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glacier985
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| Posted: Thu Apr 13, 2006 3:20 pm Post subject: |
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No Engine codes should come up with a ka24e. I personally have never seen a check engine light on my car.
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sidwin
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Joined: 20 May 2006
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Location: New Orleans, LA
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| Posted: Sun Jun 04, 2006 1:17 am Post subject: |
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so when you pull the egr off what do u use to cover up the holes? does anyone make any kind of EGR plates that you could bolt up after you remove it?
Thanks,
SId
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P4rD0nM3
Hella Old School
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| Posted: Sun Jun 04, 2006 6:24 am Post subject: |
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California cars will throw the code 32 if you remove the e.g.r.s
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sidwin
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| Posted: Tue Jun 06, 2006 8:59 pm Post subject: |
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someone needs to make a post of things u can pull off it u keep the intake manifold on the car. I don't have a welder near by that i can get to weld up holes. and what about the egr holes?
thanks,
sid
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caoboy
Driving Mom's Station Wagon
Joined: 25 May 2006
Posts: 35
Location: modesto,ca
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| Posted: Tue Jun 06, 2006 11:31 pm Post subject: |
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| for california cars, i believe you can wire up a resistor to fool the egr. even though im in california, i have a federal car (no CEL in the gauge cluster) and i think i could get away without having to put in resistors. |
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glacier985
Dont Question My Nissan Knowledge
Joined: 27 Apr 2005
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Location: Hebron, Oh
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| Posted: Wed Jun 07, 2006 7:09 am Post subject: |
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| sidwin wrote: | someone needs to make a post of things u can pull off it u keep the intake manifold on the car. I don't have a welder near by that i can get to weld up holes. and what about the egr holes?
thanks,
sid |
Just dont grind the coolant lines off the pelnum and you won't need to weld anything. And the egr just get a piece of sheet metal and cut out a plate to cover it up and use some sealant so it stays.
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SkylineKin
240sx Wannabe
Joined: 27 Sep 2005
Posts: 181
Location: Rockford, Michigan
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| Posted: Wed Jun 07, 2006 6:24 pm Post subject: |
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| awseome write up, I will definitly be using this information. |
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sr20what?
Dreams of owning a 240!
Joined: 03 Apr 2006
Posts: 86
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| Posted: Wed Jun 07, 2006 6:27 pm Post subject: |
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this is great info
one question, can i ditch the whole charcoal canister and the lines attached to it? I know you answer it but just wanted to check. |
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sidwin
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Joined: 20 May 2006
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Location: New Orleans, LA
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| Posted: Thu Jun 08, 2006 8:00 pm Post subject: |
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once u dump the charcoal canister there is going to be one line that is used for the gas can to vent. that line i would suggest you find a way to plumb it back into the intake if you don't want to smell the fumes.
I pulled my egr hose and capped it off. i also removed the solenoid that was on the top of the intake manifold.
thanks,
sid
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sidwin
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Joined: 20 May 2006
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| Posted: Thu Jun 08, 2006 8:10 pm Post subject: |
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can someone take a pic of the egr solenoid? i got the BPT off and capped all that stuff and i capped off the egr. I wish someone made egr block off plates like the do in the supra and then i could strip that guy off the intake and then plug the exhaust port too.
Thanks,
Sid
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glacier985
Dont Question My Nissan Knowledge
Joined: 27 Apr 2005
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Location: Hebron, Oh
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| Posted: Thu Jun 08, 2006 8:21 pm Post subject: |
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| sidwin wrote: | can someone take a pic of the egr solenoid? i got the BPT off and capped all that stuff and i capped off the egr. I wish someone made egr block off plates like the do in the supra and then i could strip that guy off the intake and then plug the exhaust port too.
Thanks,
Sid |
The EGR solenoid is about directly underneath the throttlebody if I remember correctly. It's hard to miss.
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nelson240sx
Belongs To The TOP CONTRIBUTING MEMBERS!
Joined: 08 Nov 2005
Posts: 1819
Location: Indy
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| Posted: Sat Jun 10, 2006 4:07 pm Post subject: |
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they do make egr block off plates for the ka24e check ebay. I just unbolted the top half of the egr the big ugly part and use the smaller piece that bolts to the throttle body. I took a piece of sheet metal and stuck it in between the intake mani and the egr and bolted it back down. I did that because i am cheap but you could spend i think it is 20$ on ebay and buy one.
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| TinyT wrote: | | for the love of god, post your setup, do you really think you can get an answer after saying HI ME CAR HAS TURBO NOW BUT I CANT BWAAA PSHH WITH IT WHATS WRONG |
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