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Ken’s Mk7 SWB crew van

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Ken’s Mk7 SWB crew van

Postby tjm07 » Thu Oct 26, 2017 9:33 pm

Thought it was a good time to start a progress thread. I have previously posted about my van (viewtopic.php?f=5&t=180567&hilit=Mk7+ticking#p1539667) and my failure to resurrect the 2.2 engine, it was the first time I had properly delved in to an engines internals and did learn a lot, just a little disappointed that I didn’t fix it. So I decided I would install the 130ps mondeo engine an idea that I found on this very forum, paul2012 has done the conversion a number of times and has been a great help to me given his time to share his knowledge so thank you paul2012. I had underestimated the scale of the job, and struggled to find the wiring looms required, but finally feel that I am making progress.
So a few pics up till now:
Dash and mk7 looms removed
5657F69B-706F-4BF2-9C7E-C10304A84254.jpeg

Engine and engine bay loom being installed
C3F05862-6782-4C7F-BBE0-E94DB14EFA89.jpeg

Dash almost back in, still some wiring to do
1FD9F32F-36A9-49F6-9EE3-01A49E3E768A.jpeg

Engine running finally after some issues with key. Mk7 van key didn’t work which I expected, I was sold a key with the new ecu which didn’t work either, but using forscan I successfully programmed a blank key to the van which was purchased off eBay for about £8.
45809A6E-3C6D-43F3-A0C2-C8D5FEE342C9.jpeg


Still lots of little jobs to do, mainly wiring mods and tidying up
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2008 Mk7 Swb transit crew bus 85ps
2002 BMW 320d e46 204k and counting
2005 Vauxhall astra sri
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Re: Ken’s Mk7 SWB crew van

Postby tjm07 » Thu Oct 26, 2017 9:52 pm

So a couple of other mods along the way,
To save replacing the inter cooler for one with a map sensor I machined a nylon insert to mount the sensor in
64027E4B-50CB-4554-9D85-FFC81DE014E7.jpeg
26227DE7-0C01-4E56-B223-17D2C1EFCDCB.jpeg

Also machined a nylon adapter flange to mount a mk6 maf sensor in the mk7 air pipe to allow me to use the mk7 air box, which I know will mean removing air box to access oil filler but some wing nuts and quick release clips will make this no issue.
540356CC-D00B-4D90-BF8D-C07179E82EBF.jpeg
these adaptations are untested and may not work out the way I hope but fingers crossed

I also painted inside of the headlights and the front bumper whilst I was sourcing and awaiting parts to arrive
E889D3B8-89B1-4166-ABA9-337777979076.jpeg

So that’s pretty much where I am at, the back of the van is a state, tools, old looms, bits off the old engine, printouts everywhere.

So I have had engine running but only briefly due to not having the cooling system fully plumbed in. Now have all the hoses required so over the next few days that’s what I am hoping to get done, and run the engine for a good period
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2008 Mk7 Swb transit crew bus 85ps
2002 BMW 320d e46 204k and counting
2005 Vauxhall astra sri
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Re: Ken’s Mk7 SWB crew van

Postby tjm07 » Fri Nov 03, 2017 8:10 pm

Have had van running now, taken it for a small test drive, got fault code p0235 (map sensor). Reset and see what happens. Could do with a pin out diagram of the plugs behind drivers side dash that the loom that runs down to rear of van plugs into if anyone has one?? Managed to get rear light cluster working, side loading door, but left with a handful of wires, lots of black and blues, so a pin out would be a real help. Thanks in advance.
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2008 Mk7 Swb transit crew bus 85ps
2002 BMW 320d e46 204k and counting
2005 Vauxhall astra sri
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Re: Ken’s Mk7 SWB crew van

Postby tjm07 » Sat Nov 18, 2017 8:45 pm

Now with a years MOT! Still lots to do but a big step in the right direction. Ply for the rear next me thinks.
2008 Mk7 Swb transit crew bus 85ps
2002 BMW 320d e46 204k and counting
2005 Vauxhall astra sri
tjm07
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Re: Ken’s Mk7 SWB crew van

Postby tjm07 » Mon Dec 04, 2017 6:30 pm

Bit of progress. Ply laid in half of the rear, carpet laid and rear seats bolted in at long last
141BCB36-9E5B-4ADB-A65F-1E9A68CFD9B5.jpeg

Also made some side bars from some 2” stainless tube, needs a good buff and polish though
7ACF4C04-B4C0-48F4-B4E9-E1377C67A2CB.jpeg

Now I’m on the ponce, anyone got a pin out or diagram of the plug for the rear lock, still trying to splice a mk6 and mk7 drivers body loom together, I’m down to the rear door lock but my eBay Spanish converted drawings are a bit lapse on the body looms.
497737D7-F282-4B7B-84C5-3B9EF4E40295.jpeg
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2008 Mk7 Swb transit crew bus 85ps
2002 BMW 320d e46 204k and counting
2005 Vauxhall astra sri
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Re: Ken’s Mk7 SWB crew van

Postby paul2012 » Tue Dec 05, 2017 5:55 pm

Wiring diagrams for mk6 side loading doors, Rear doors, Rear Tailgate. 8)

Side loading doors.

MK6 CL SIDE LOADING DOORS.jpg


Rear doors

MK6 CL REAR DOOR.jpg


Rear Tailgate

MK6 CL REAR TAILGATE.jpg
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Re: Ken’s Mk7 SWB crew van

Postby tjm07 » Tue Dec 05, 2017 7:18 pm

Thanks Paul, a big help.
2008 Mk7 Swb transit crew bus 85ps
2002 BMW 320d e46 204k and counting
2005 Vauxhall astra sri
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Re: Ken’s Mk7 SWB crew van

Postby tjm07 » Sun Jan 07, 2018 9:14 am

Half bulkhead being fitted and also aux switch board with voltmeter, usb charge point, and extra lights
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2008 Mk7 Swb transit crew bus 85ps
2002 BMW 320d e46 204k and counting
2005 Vauxhall astra sri
tjm07
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Re: Ken’s Mk7 SWB crew van

Postby Wardktm » Sun Jan 07, 2018 10:45 pm

Looking good mate, I’m watching closely for when I do my conversion, what clocks have you used??
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Re: Ken’s Mk7 SWB crew van

Postby tjm07 » Tue Jan 16, 2018 7:22 pm

Wardktm, they are just later mark 6 transit clocks with rev counter, they require a bit of trimming to make them fit (mainly on the ‘pocket’ in the dash that the clocks sit in) I understand that afterwards you can warm the cowling with a heat gun to reshape it slightly to neaten it up, which I haven’t done as yet.
2008 Mk7 Swb transit crew bus 85ps
2002 BMW 320d e46 204k and counting
2005 Vauxhall astra sri
tjm07
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Re: Ken’s Mk7 SWB crew van

Postby tjm07 » Sat Jan 20, 2018 8:31 pm

Finished off the bulkhead this afternoon, also started insulating behind the ply lining. Managed to find a mk6 tourneo in the breakers so stripped out the body loom to replace the spliced mk6-mk7 loom that has been causing me agro for weeks, so my interior lights work as they should along with sld lock, tailgate not locking though, more investigation required. Someone tell me about mk6 handbrake lights? I have read that mk6’s don’t have a light on the dash, I have what I would say was a handbrake light on the dash, but after reading they don’t have one, what does the light mean?(brake fluid reservoir not low, already checked) thanks
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2008 Mk7 Swb transit crew bus 85ps
2002 BMW 320d e46 204k and counting
2005 Vauxhall astra sri
tjm07
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Joined: Wed Dec 01, 2010 9:42 pm
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