Sockets – 10mm / 17mm / 19mm
Ratchet
Torque Wrench
Soft faced hammer or mallet
T45 Torx
Scotch Brite Pad
Brake Cleaner
Red Threadlock
RTV

For Clutch Install
Centering tool (or deep socket of correct size)
Blue Threadlock

Normal 0

Before installing the SK-A, take a few minutes to clean the face of the Zetec paying special attention to removing any rust on the crank snout and the hole in the crankshaft where the pilot bearing will sit.  A Scotchbrite pad and some spray brake cleaner will clean this up nicely.  

Replace the crankshaft position sensor cup with the one provided in the kit.  Be sure to replace this part now, as you will not be able to get to it once the adapter plate has been installed. 

Insert the black plastic inspection plug in the hole in the lower right section of the dust cover from the back side.

Align the locating pins on the Zetec with the locating pin holes on the adapter plate.  This will be a very tight fit, so use a soft faced hammer or rubber mallet to tap the adapter plate flush with the dust cover on the face of the engine block.

Once the adapter plate has been aligned and flushed up, make a mark along the bottom face of the engine block just below the adapter plate with a scribe or a marker.  If desired, this section of the engine block can be cut away using a hacksaw with a metal cutting blade to increase ground clearance.  The dust cover should also be cut away where the adaptor plate does not cover the shield at the top right where the original Zetec starter would normally be attached. 

Install the adapter plate bolts and studs following the specs on the diagram included below.  Use red threadlock on all fasteners except the starter bolt.  The two 50mm bolts at the top thread through the front of the adapter plate into the engine block.  The remaining bolts thread into the adapter plate from the backside through the holes in the engine block and dust shields.  The transaxle mounting studs should be installed through the front of the adapter plate so that they just make contact with the dust shield on the engine block.

Align the starter block-off plate behind the dust cover and mark along the inside opening with a scribe or marker.  The shape should be somewhat like a smiley face.  Apply a bead of RTV sealant just to the outside of the marks and then install the plate with the included 6mm bolt.  Do not over tighten the bolt or you may deform the block-off plate from making a complete seal.

Insert 3 flywheel rolled pins from the stock Vanagon flywheel into the non-threaded holes in the outer face of the flywheel.

Install the flywheel onto the crank snout using the provided crank bolts. Make sure to use red threadlock on all fasteners. Fasten the flywheel crank bolts in a cross diagonal (star) pattern to insure consistent even pressure around the disc.

Once all of the bolts are snug, lock the flywheel in place using the provided flywheel tool placed between the starter gear ring on the flywheel and one of the mounting studs. The crank bolts should be torqued to 80 ft/lbs.

Place the clutch disc on the flywheel and insert alignment tool or dowel to insure that the disc is perfectly centered.

Position the clutch pressure plate over the flywheel rolled pins so that the bolt locations line up with the threaded holes in the flywheel.  Apply blue threadlock to all bolts and snug down each bolt until they are all finger tight. Tighten bolts a turn at a time in a cross diagonal pattern until they have fully seated the pressure plate. Torque all bolts to 20 Ft-Lbs. Remove the alignment tool.