Bostig Factory Manual
Total Page:16
File Type:pdf, Size:1020Kb
Bostig Factory Manual G22 "The good life is inspired by love and guided by knowledge" -Bertrand Russell Introduction: Confidence, value, and education are the core goals of the Bostig Conversion System. It has always been our goal to provide the customer with a complete and comprehensive guide to follow throughout the entire process. Thus the written instructions and videos have evolved along with kit as it has progressed over the last 8 years. This guide will help you complete the conversion from start to finish, and help you to develop confidence and familiarity working with the conversion. It covers all of the online material. The guide is also a reference which will help to keep the proverbial mole hill from turning into a mountain. We've shaped the guide based on years of feedback from customers and careful study of the conversion in order to help make things progress as smoothly as possible. The guide is broken into Pre-install, Install, and Post-install. Inside of the guide you will also find parts lists for each of the provided sub kits. Some sections also include references to installation videos. These videos will have basic overviews which will accompany them to aid in the conversion process. This factory manual puts Bostig in a league of its own in the engine conversion market. There are no kits as complete as the Bostig Conversion System, and no other kits come close to the level of documentation that the Bostig Factory Manual and videos provide. Thank you for choosing the Bostig Conversion System and if you have any questions or find discrepancies in the guide please let us know. -Jim, Brady, and Kyle 1 INTRODUCTION: ................................................................................ 1 SK-In Instructions ....................................................................................... 63 PRE INSTALLATION ............................................................................. SK-In Cooling Hookup ............................................................................... 64 Overview ........................................................................................................... 3 SK-In Power Steering ................................................................................ 71 Do’s and Don’ts ............................................................................................... 5 Speed Sensor/Ring Instructions........................................................... 73 Required Parts list......................................................................................... 6 Brake Booster line Instructions ............................................................ 74 Tool and Workspace Preparation .......................................................... 7 Decklid HS Instructions ............................................................................ 75 Engine Inspection and Preparation ....................................................... 8 Throttle Cable ............................................................................................... 79 Engine Preparation Checklist ............................................................ 9 Automatic Transmission notes ...................................................... 82 SK-A Partslist ................................................................................................11 Serpentine Belt Routing ........................................................................... 83 SK-A Instructions ........................................................................................13 SK-In Engine Oil ........................................................................................... 85 SK-C........................................................................................................... 17 Cam Timing Check/Reset ........................................................................ 86 SK-C Instructions ........................................................................................19 POST INSTALLATION ........................................................................... SK-M ......................................................................................................... 23 Overview ......................................................................................................... 89 SK-M Instructions .......................................................................................25 SCT Instructions ......................................................................................... 90 SK-E .......................................................................................................... 29 Elmscan5 Scantool ...................................................................................... 92 First Run Instructions ............................................................................... 94 SK-E Instructions ........................................................................................31 Around the Block ......................................................................................... 97 SK-I ........................................................................................................... 35 APPENDIX ................................................................................................ SK-I Instructions .........................................................................................37 Torque Specifications ............................................................................. 100 SK-W Instructions ......................................................................................41 Required Tools List Explanations ..................................................... 102 ECU Chip Installation .................................................................................48 Rock Auto Order List .............................................................................. 107 MIL light Installation ..................................................................................49 Engine Call Sheet ...................................................................................... 109 Tachometer Resistor Modification ......................................................51 Power Steering Pump Call Sheet ....................................................... 112 SK-In ......................................................................................................... 55 ECU Call Sheet ............................................................................................ 114 Configuration Box ............................................................................... 56 Torque Converter and Flexplate Prep/Fitment ......................... 119 Configuration Box ............................................................................... 57 Maintenance Schedule ........................................................................... 120 Configuration Box ............................................................................... 59 Configuration Box ............................................................................... 60 Additional required parts ................................................................ 62 2 Pre Installation Overview Prerequisites Ability to read, or access to someone who can. Windows XP or Windows 7 computer with USB port, or access to one. Internet connection or access to one. Willingness to learn about the conversion process and what it takes to keep your own van on the road. Basic tools(metric for virtually everything), wheel ramps/jack, and basic knowledge of their use. Phases of the conversion process The conversion and its documentation are broken down into three phases for ease of completion, and consistency of results. 1. Pre Installation 2. Installation 3. Post Installation Kit Hardware Organization The kit is broken into "Sub-Kits"(SK) based on functional and chronological order. The order and names of the sub-kits can be remembered by use of the mnemonic devise "ACME - I Win". Unlike ACME however, if Wylee E. Coyote had bought a kit from Bostig, he would have been eating roadrunner instead of beating himself up. 3 Pre-Install Install Post-Install Elmscan5 Read Inspect Around the SK-Adapter OBDwiz Overview Trans Block Overview or Read Inspect SK- SCT Required and Prep SK-Cooling Mounting Software Inspect Parts list Parts Continued Installation Read Call Engine First Run Drive 100 Sheets Preparation SK-Mounting SK-Exhaust Inspection miles Read Rock Check Prepare Check 100 Mile Auto Order Cam Van For SK-Intake Other Van Inspection List Timing Install Systems Long Term Read Air Box Remove Log/ SK-Wiring Maintenance Required Mod Old Engine Monitor Tools List Schedule Separate Prep Work SK- Complete Place Engine/ Area/Tools Installation First Run Orders Trans IMPORTANT NOTE FOR AUTOMATIC TRANSMISSION CONVERSIONS! DO NOT! have your Automatic Transmission or Torque converter rebuilt just prior to the conversion process. Leave the setup which has been working in your van for at least 3000 miles after you've completed the conversion. This is crucial to determine that everything is working properly on the conversion without other variables. If you have any questions or special circumstances please give us a call regarding this. 4 Do’s and Don’ts for Bostig Conversions In no particular order your oil changes every 3k-5k contact us with questions use new oil before your first run DO DO DO Doing oil changes on time is the single most important thing you It’s part of what you paid