Stan Buys a Minivan  Page 2
How to make a monster out of the Family Grocery getter

Is that a speck of dust?  Quick, brush it off! The transmission has to be clean before it goes back!
Re-installing the front suspension
I made a bracket for the rear transmission mount and bolted it securely to the front lip of the K frame.
The elusive parts necessary to make a five speed van - clutch and brake pedals, clutch cable, cable bracket, and shift mount bracket. Not pictured is the plastic shifter cover trim.  All these parts have to come from a van that was built with a 5 speed box! The shifter, flywheel, and clutch are the same as any 2.5TI car. A shifty proposition
You're SO smart Dad! The engine block finally makes it back to the van.  Next, I'll put in the larger Garrett TII turbo and let's not forget the 3" exhaust!
What this van needs is a little INTERCOOLER!  This shows how I installed a Huge Volvo intercooler in front of the radiator.  I had to remove the bumper, grille, headlights and radiator to get this thing in. The inlet and outlet are at slightly different levels, so the intercooler is mounted slightly crooked to position the inlet and outlet just above the structural box member which supports the front engine mount.  Two "L" brackets and a tie-wrap hold the intercooler in place.  Rubber isolaters keep the intercooler from chafing against the body and AC condenser. AHA!  It fits!
This picture shows how I cut holes in the sheet metal for the intercooler tubing. There was just barely room for the hose below the A/C condenser.
The intercooler inlet piping consists of three pieces - a radiator hose from Autozone, a piece of metal intercooler piping from an Isuzu, and part of the Volvo intercooler hose.  Everything fits perfectly!  The hose deftly dives between the clutch arm and the cruise control.  The radiator, however, had to be shifted 1 1/2" to the left (as viewed from the front of the van) to clear the intercooler hose. intclrhs.jpg (38025 bytes)
To move the radiator, I relocated one mount on the radiator and relocated the other on the body. This picture shows the new mount (made of a bolt and washer) glued to the lower radiator tank.
Here is the Blow off (or turbo bypass) valve.  The valve is installed and modified per Gus Mahon.  You can see the pipe from the intercooler outlet as it enters the engine compartment just below the AC condenser.  Of course, the BOV is painted to match the engine!  The filter is a K&N breather element. Gus recommeds a sock, but I did not have one that matched the engine color :) vnbov.jpg (48074 bytes)
vaneng13.jpg (81393 bytes) Looks good and runs GREAT!  I hardly notice the absence of balance shafts.   The van easily smokes both tires.  I've been wanting something like this ever since I was inspired by a picture of Gus's van "heating the hides"!  Once the engine is broken in, it's time to add fuel and raise the boost.  The van carries all five kids to school each day, so break-in time will be over in a hurry.
This van doesn't need a chrome exhaust tip!
A dual pillar pod houses the boost and air fuel gauges. I used a gauge pod made for a mustang. I persuaded the pod to fit with a little assistance from a heat gun. The pod mounts with six fasteners and JB weld. The JB weld will not stick unless the plastic is roughed up. Even when the plastic is rough, the adhesion is somewhat dubious, so the fasteners make sure pod stays in place.
An interior view showing the shifter and gauge pods.