Hyunwoo Yang Week 2

Installing new thermostat

Clean the area where thermostat housing and engine block contacts.

Clean the bolts and light paste the Anti-Seize at the threads

Punch a small hole about 1⁄4” from the outer edge of the thermostat.

install the t-stat into the housing with the drilled bleeder hole to the top(12 o’clock).

Install the thermostat housing onto the head with the M8-90mm bolts and washers.

Torque to no more than 18ft/lbs.

Matt Week 2

Matt Week 2

This week I worked on preparing the rear side of the engine to eventually be connected to the VW transmission. The first thing I did was modify the CPS module to work with the new flex plate with parts from Bostig. Shown below is the sensor fitted with it's new parts. Note the two M6 spacers in between the back sensor and the sliver module. They are critical for the sensor's spacing from the flex plate.

New custom shims have also been installed to fit properly with the transmission adapter shown below.

Below the lower shim, there was excess metal that was used to fit with the original Ford transmission. It is no longer needed and was cut off with a metal to raise ground clearance. Above you can see the extra metal poking out below the lower shim. Below is after I cut off the metal. Nice and flush with the new adapter.

Lastly, I installed the new transmission adapter plate from Bostig. It was a tight fit and required a rubber mallet to force into place. The new plate looks great on the engine as it gets closer to being fitted with the VW transmission. Below is the adapter installed on the engine, not yet bolted on.

Jarred Week 2

The Project Continued......

Me and Zach continue working on the camper and dealing with all the problems that come along with it

The main goal is to remove the engine, so you have to remove all pipes/electrical components/other components such as the air filter.
Friday was the removal of the coolant that was left over from the camper.

Monday was when we worked on the bottom of the camper by removing or disassembling
 tubes and pipes that were connected to the engine.

Tuesday is when all the components that were neatly put aside on a moving cart, it to be stored into the camper for use after the new engine is installed. Laying down a tarp on the floor of the camper was to prevent dirty, coolant, and hardened exhaust from dirtying the floor.

Zach Week 1

Jarred and I are working on removing the boxer engine as well as the trans-axle from the Westy. On Tuesday we drained the coolant, and removed the axles off of the trans-axle. We had some difficulty removing the axles. The right side was a 6 mm Allen, and the left side was a M8 triple square. The bolt heads needed to be cleaned thoroughly in order for the bit to fit properly and not strip the bolt head.

Wednesday we disconnected the battery. In order to do this we had to slide the seat off of its mounts. we removed the coolant loop from around the engine bay. We also removed the heat shields on the left and right of the engine in the wheel wells. These are going to be reused so its important to keep them organized and in good shape. Lastly we took the bolts out of the rear heat shield that goes over the exhaust pipe. The bolts are mounted onto the cradle that supports the engine so in order to remove the engine they must be removed.

Thursday we worked on the top of the engine. We removed the air box, coolant hoses, gas hoses, and electrical. We removed the rear right tail light to get access to the idle stabilizing unit that is mounted behind it. This is important because this is connected to the wiring harness that must be moved out of the way in order to lower the engine out without catching on any loose wires.



Friday we disconnected the distributor and took a picture so we can remember where all the wires attach since it will be reused. We finished removing the electrical and hoses from the top of the engine, then switched our focus to removing hoses and electrical from the bottom. We removed a sensor that goes into a coolant hose that was lower than our drainage point so we made a little mess. We will be ready to remove the engine and trans-axle next week.

Jarred Week 1

A Project in Progress

This time I have to work on something that I have no real ability in. Removing a engine from a camper van so that it can be replaced by a better Ford engine.

We first went to the back of the camper and removed parts that were connected to the engine.
The only hard thing was removing a section of the engine that was connected by the worst placed bolts ever

Thankfully, we had a big enough extension for the ratchet to be able to remove it
We also drained the coolant that was still in the car so that we could start removing the tubes that were connected to the engine.

We also went under the camper to remove parts such as the heat shielding from the bottom as that is where the engine will be removed from the camper.

Other parts were removed as well such as the throttle controller as well as the fuel line in which we plugged up so that it wouldn't leak.

Exhaust removal

Remove the catalytic converter

Remove exhaust manifold and clean.

Matt Week 1

I am close to wrapping up the timing belt replacement on the Ford Zetec engine that I have been working on for the past two weeks. The belt itself along with new tensioners were replaced today and all that remains to be done is putting everything back together. A new water pump was also installed while everything was taken apart.

Welcome to the blog site for the Rockway Mennonite Collegiate Grade 12 Transportation Technology class project!  The  plan for this unique and exciting project is to convert a 1987 VW Westfalia van to be powered by a 2.OL DOHC Zetec Ford engine. 

The picture on the right shows the "Westy" being prepared to begin removing the VW engine.



The Bostig conversion kit is being used, which supplies all the components to make the conversion to a Ford engine possible.  The intent is to replace the original water-cooled boxer engine with a more powerful and more reliable Ford inline 4 cylinder.  Who would have thought a VW could be upgraded with a Ford engine?  Stay tuned for  student posts as they make progress on the project.

The 2.0L DOHC Ford "Zetec " engine, which was removed from a 2003 Ford Focus.  Regular maintenance and some modifications are needed to prepare the engine for the conversion.