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Old 29-12-2018, 05:48 PM   #1
will16
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Default K20 Maestro Van

Hi Guys,

Thought I'd start a thread for my new project. I've always like vans, always fancied a quick van, I like old british pineapple too so I ended up buying a Maestro. It was the cheapest and quite possibly the worse condition one I could find . 234K Perkins diesel, absolutely gutless! Ive has a EP3 engine sat about for about a year now after I got it cheap when my mate wrote his civic off, and as they say the rest is history... I'll let the pics do the talking

Untitled by Will Giddings, on Flickr

Untitled by Will Giddings, on Flickr

Untitled by Will Giddings, on Flickr

Untitled by Will Giddings, on Flickr

Untitled by Will Giddings, on Flickr

Untitled by Will Giddings, on Flickr

Untitled by Will Giddings, on Flickr

Untitled by Will Giddings, on Flickr

Battery is worth more than the van

Untitled by Will Giddings, on Flickr



Untitled by Will Giddings, on Flickr

Untitled by Will Giddings, on Flickr

Untitled by Will Giddings, on Flickr

More tomorrow

Last edited by will16; 30-12-2018 at 10:33 PM.
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Old 30-12-2018, 10:16 AM   #2
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Looking good!
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Old 30-12-2018, 12:43 PM   #3
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That's bloody brilliant, love it.
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Old 30-12-2018, 07:21 PM   #4
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Looking good!

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That's bloody brilliant, love it.
Thanks guys

Engine mounts are finished, boxed in. Made a rear engine steady bar too, solid subframe end, poly engine end. The civic has one front and rear but there isnt really a place to put one at the front. I'm hoping with the two large poly engine mounts and the rear bar should be enough to hold it! Made a mount for the gear shifter, ep3's have a van style shifter coming out the dash and I quite like that, the box I've made is a bit big, but its in a comfy place. Handily, Austin Rover forsaw people doing this conversion and left a blanking plate in the bulkhead for the cables to pass through Exhaust is also done, these engines respond well to breathing mods so I wanted a 3" exhaust, picked up a subaru one for 40. Had to cut it about to raspberryy but wasnt anymore work than starting from scratch. Dont mind the boy racer 5" tip












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Old 02-01-2019, 08:26 PM   #5
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Not really done much to it over the last few days, loom is in, another Austin Rover convenient hole behind the glovebox Engine turns over but there is problem with the key / immobiliser judging from the dash lights. Modded the fuel tank too to take the civic pump / sender unit. I might cut an access hole in the rear bed to save dropping the tank if theres any issues and because I dont think theres enough height for it either haha.











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Old 02-01-2019, 09:48 PM   #6
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Yes mate!! Love this so much!! Progress is looking good


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Old 03-01-2019, 07:19 PM   #7
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Yes mate!! Love this so much!! Progress is looking good


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Cheers man! Sorta of getting there haha

Bit more done today, been going round in circles unfortunately. Relocated the battery behind pass seat and fitted the tank. The pump wasnt priming for some reason, then its magically started working. Not getting any spark though, which I think is to do with this immobiliser problem . They green key light keeps flashing, there is no reason why it is doing this and why it doesnt run, apart from the immobiliser or key has gone bad (just my luck haha). Gonna have fiddle tomorrow, if I cant get it going its gonna need an immobiliser delete. Little disheartened as the plan was to get it running and driving by the weekend.

Ignore how messy it is



Got my measurements right

Untitled by Will Giddings, on Flickr

The bloody light!

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Old 04-01-2019, 08:31 AM   #8
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like this allot ... assume you think you have all the parts for the mobiliser ?
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Old 05-01-2019, 06:54 PM   #9
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like this allot ... assume you think you have all the parts for the mobiliser ?
Cheers Matt, yep using all the matched set. I did a fair bit of research into it and its a common problem with EP3's. There are a few ways to cure it, send it to Honda or get a decent mobile auto electrician and they can recode the key to the immobiliser, get a immobiliser bypass box or get a new ecu, either a demobilised standard one or aftermarket type.

Well, today wasnt succesful in the slightest. I rang my local Honda and explained to them the immob problem, they concurred that they had done a couple cars, they said they could do it, then I said what the engine was in and they said they wouldnt be able to help . Facebook proved a winner and found a guy who has a standard ecu with immob disabled. I tried my clutch bracket, which didnt work. I think the cable is just stretching as you can press the pedal and the clutch arm barely moves.

I tried my driveshafts too and chopped the front springs whilst they were out. Couldnt get them properly in as well as putting the upright in. I think one of them might be too long . Started getting annoyed so packed up and raced up to birmingham to get the ecu. Got back and thought sod the shafts, put the front suspension back together. Put the lowering blocks on the rear too which was a pain as I had to redo the handbrake cables.

After I'd put it back on its wheels I thought I'll start it, I wanted to put a filter on it, so took the intake pipe off. Thank god I did, as petrol poured out. Probably around 2 litres of the stuff. Absolutely no clue why. I thought it might of been because I was priming the pump and trying to start it yesterday? I took the plug off the tank so I could turn the ign on. I think there was about 1/4 of fuel in it on the gauge, now, there is absolutely nothing showing on the gauge . I think the fuel pump has randomly pumped the tank dry, into the engine. Either that or there is a leaky injector(s). I've taken the plugs out and am leaving it tonight to try and evaporate it. It's gonna need an oil change too I'd imagine, I'm praying that the bores havent been washed too badly. What do people think?

Also, the gearbox CV joints are further forward than the hub CV joints, this is because I had to position the engine where it is due to the exhaust - bulkhead clearance. I thought this would be ok for the joints to cope with, but I'm thinking now maybe it wouldnt be ok









CV Joint angle


Last edited by will16; 05-01-2019 at 07:26 PM.
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Old 06-01-2019, 04:59 PM   #10
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Mojo restored . Went to bicester sunday scramble this morning, lots of cool motors. I'd wanted to take the van lol. Came back and was having a look with a couple mates, I worked out why there was fuel pouring into the intake, I followed the lines round and found I'd connected the fuel feed line to the port where the brake booster vacuum line goes IDK whether to laugh or cry. Dont think its done any damage. Never, ever rush a build New ecu in and fuel sorted means it will now run, very lumpy and rough but it has fairly sizeable exhaust leak and no lambdas plugged in. I put the engine garnish on too






Last edited by will16; 06-01-2019 at 06:53 PM.
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Old 06-01-2019, 08:24 PM   #11
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Well there's bound to be a few grapes ups along the way!

Good progress
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Old 06-01-2019, 10:43 PM   #12
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i am amzed how much u have done in the time, i need some motivation like that
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Old 07-01-2019, 04:37 PM   #13
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CV angles should be ok .. just give it go .
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Old 07-01-2019, 05:24 PM   #14
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Love this!!
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Old 10-01-2019, 09:59 PM   #15
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Well there's bound to be a few grapes ups along the way!

Good progress
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i am amzed how much u have done in the time, i need some motivation like that
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CV angles should be ok .. just give it go .
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Love this!!
Cheers chaps

Not done a great deal, after I missed the weekend deadline, I'm not gonna rush anything else haha. Modified the throttle cable to use the maestro bulkhead fittings and made a cable clamp on the lathe, need to check that its opening the throttle body all the way. Also got the shafts in, they are a little long but there is enough room for them to move, time will tell tho Did the heater hoses too. Going to order some mk2 golf coilovers on payday for the front as the current struts are shagged







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