Converting the engine in a 1990 Vanagon from stock to a Ford 2.0 liter Zetec engine, using the project kit and support supplied by Bostig, Inc. (www.bostig.com). This blog was started in case anyone wanted information about the actual conversion. I'm not sure anyone does, though.
Saturday, October 22, 2011
So, we actually started the project in late September, with the acquisition of a used Zetec engine. I found an '03 with 13,000 miles within driving distance, and picked it up in the F150, carrying it home on a pile of used motorcycle tires. Having both a truck and a bucket tractor (and a logging chain) made this easy. The kit from Bostig - ten boxes via UPS - arrived shortly thereafter, and I hoped to begin in early October. However, I encountered a series of schedule delays due to other events, and put off the start until we got through them. I should add that the green puddle that started all this turned out not to be the head gaskets after all. Our Volvo V70 wagon's power steering had a problem, Joan needed to travel (it's her van), and I decided to try to locate the leak and see if it might be a problem that leak-stop could fix. I was reluctant to use such a product, fearing possible clogging of the radiator. I ended up finding that a plastic pipe connecting to the cylinder bank had a minute crack in it. After removing it and making numerous attempts to patch the crack, I located a replacement pipe (made of metal!), fashioned a gasket (the original gaskets are NLA) and installed it. The engine leak was completely stopped. However, I have no plans to delay the installation further, though being able to use the van over the last several weeks has been great for Joan. The V70? Another *&^!%$^% plastic part failure. I have also just fixed the odometer in the Vanagon for the xxth time. It has a PLASTIC drive gear that is a friction fit on a metal drive shaft. What could go wrong? the designer thought. Twenty years later ...
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