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SK-In, Install Sub-Kit part 1 of 2 |
The SK-In is the only Sub-Kit in which we will break down the tasks within the sub-kit. The SK-In will touch on many of the systems you have worked on already. Expandable sliders below each video contain additional information.
print slider contents Rear Mount
With the engine assembly in place, sitting with a 3-4 inch gap between the deck lid rim and the top of the cam cover, lift the rear mount assembly into place where it will attach to the body of the van, right below the rear hatch latch, just above the license plate door.
With the rear mount assembly on the studs for alignment (but without nuts installed so it can move up and down), the rear mount will generally sit approximately 1/2" to the left (drivers side) of center. Use your Sharpie to mark the group of 4 holes in the bracket onto the body of the van.
After marking the mounting location, remove the entire rear mount assembly from the engine. Disconnect the upper mounting bracket from the assembly for installation.
Center punch and drill the 4 horizontal mounting holes with an 11/64" drill bit (you may substitute a 3/16" bit if 11/64" is not available).
Mount the upper bracket into place with the supplied #14 sheet metal screws using a 3/8" socket. Torque these fasteners to 68in/lbs.
Once the 4 top screws of the upper bracket are in place, but with the rest of the rear mount assembly removed, working from the bottom of the engine bay, center punch and drill (11/64" bit) the three fastener locations on the bottom side of the upper mounting bracket. Install the 3 remaining #14 sheet metal screws and torque to 68in/lbs.
Using a 13mm wrench, tighten the 4 cradle to frame bolts to 37 ft/lbs.
Put the lower rear mount assembly back in place loosely on the engine. Position the rubber hanger donuts on the lower assembly into the upper mounting bracket and join them together with the 120mm bolt. . Tighten the 17mm nylock nut to 18ft/lbs.
Tighten the two 19mm M12 nuts and washers on the lower bracket studs to 45ft/lbs. print slider contents
Throttle Cable
Route the supplied throttle cable following the stock routing. Be sure to install the cable through the same rail openings as the original path or the cable will not be the correct length.
The throttle cable is installed from the REAR of the van to the FRONT. Pass the threaded stud end of the throttle cable through the original throttle cable holes in the crossmembers towards the front of the transmission.
The original throttle cable black plastic retainer must be reused. Remove it from the stock cable, clean the retainer as necessary, then pass the new cable through the retainer and slide it forward into the stock front cable housing.
Connect the threaded stud to the pedal assembly with the stock bolt, making sure to take the slack out of the cable as necessary. Test operation with a helper watching the throttle body plate. If the cable is badly out of adjustment, move the throttle cable adjuster to a new hole in the adjustment fin. Use medium thread lock and do not use excessive force on this fastener, as the stud is aluminum. Once the rough adjustment has been made, make the final adjustments with the threaded barrel adjuster.
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Oil Pan Install
The stock Zetec oil pan and pickup is not used with the Bostig conversion. The oil pan provided in the kit will provide increased ground clearance while maintaining full sump capacity.
Drain the oil from the engine and remove all of the bolts that hold the oil pan to the crankcase.
Remove the stock oil pan by hammering a putty knife between the oil pan and the crankcase. The factory sealant is incredibly strong, so considerable force will be needed to break the seal. Using the putty knife, carefully cut around the outside perimeter of the oil pan until it comes loose and then remove it from the engine.
Remove the stock oil pickup and then wait until all oil stops dripping from the engine before proceeding.
Clean all of the old sealant off the crankcase with a scraper and degreaser (brake cleaner works well for this purpose). Be sure to degrease the new oil pan and oil pickup as well.
Place a thin layer of RTV on the new oil pickup tube and install it with the original fasteners using thread lock. Torque to 89in/lbs. Do not reuse the original rubber o-ring with the new pickup.
Apply RTV to the new oil pan and the engine crankcase surface. Be sure to completely surround all fastener locations with RTV to prevent leaks. Allow the RTV to set up for 20 minutes and then install the oil pan following the tightening sequence below.
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