Vanagon List,

I have just finished a large project with my 91 GL and thought I ought to
share my experiences with the list.

Engine:
I knew I had some leaking heads as soon as the cold weather set in, but
hoped to ignore it for a while.  I kept the 20-50 oil too long and as soon
as it got really cold, I blew out the O-ring between the oil cooler & the
block.  At that point, I took the bus off of the road and drove an 86 that I
have.  The mileage on the 91 was now at 99,853.  I thought things through
and decided that I wanted to make the 91 a very trustworthy vehicle that I
can take anywhere I want, anytime I want.  One of things this meant to me
was an engine rebuild even though it was premature at less than 100,000
miles.

I have rebuilt quite a few engines in my life.  In fact, I rebuild 50's &
60's Lancia engines as a little side business.  I priced the parts that I
felt I would need in preparation for doing it myself.  Now, I will never buy
a rebuilt engine (or any other part) from a factory because I can't be sure
of the quality.  But after lurking on this list for some time, I have been
very impressed by Boston Bob (Boston Engines -bostneng@fci-us.net ).  When I
priced a rebuild from him, it was less than $200.00 more than the parts
would cost me.  I started to correspond with Bob and after asking him a
number of questions, I decided to go with one of his rebuilds.  I sent him a
check & he started to work his magic.  One of things I really appreciated
was that he was very eager to communicate.  He always answered e-mail very
quickly & gave me options as they arose.  I never had to wonder if my
investment was safe.  The engine arrived right on schedule and I have
finally installed it.  I was only able to put 225 miles on it before I had
to make a trip from Pittsburgh to Philadelphia and back.  I changed the
break-in oil and put the 20-50 in a little early, but it ran like top all
the way across the state.  I varied my speed quite a few times to help with
the break in and stopped about half way and let the engine cool down before
continuing.  Coming home was a little different.  I was ready to get home,
so a ran it up to about 80 MPH and flew over the Turnpike. I used NO oil on
the trip and it is still real clean.

Engine accessories:
I had the intake manifold box & tubes, crank & water pump pulleys, engine
support bar, and miscellaneous brackets powder coated in satin finish black.
I installed a rebuilt starter, but kept the original alternator.  I had
bought a new set of motor mounts from the Bus Depot, but Bob was afraid they
might be from South America, so I ordered a second set from him.  Well, it
turns out both sets were identical and German, so I now have a spare set.

Cooling system:
I replaced the rear heater core last year.  Boston Bob sold me all of the
engine hoses at a very good price.  I added the hose between the plastic
tube & the plastic distribution manifold and the hose between the other
plastic tube and the thermostat housing.  I got these from the VW dealer as
they were last minute decisions.  I also replaced the Thermostat housing and
the distribution manifold with factory parts.  While I was at it I got a new
reservoir tank & cap from the Bus Depot and a new water pump from Ken
Wilford ( vanagain.com ). Boston Bob supplied an 80 degree thermostat as he
thought my 86 would be too hot. I replaced the coolant with phosphate free
anti freeze.

Exhaust:
I initially thought I would just put on my existing exhaust system, but as
the time drew near, I talked my self into longevity.  My muffler brackets
were about half rusted out and many of the pipes were rusty looking.  I bit
the bullet and ordered a Stebro muffler from Frank Condelli in Canada ( I
can't seem to find the URL or E-mail address - Sorry).  Now that I had it
coming, I figured I would just go ahead and get the stainless head pipes fro
Ron (Bus Depot).  Well, if one is going this far, why not a new cast iron 2
into 1 and a J-pipe.  I stripped these last two parts and painted them with
1200 degree exhaust paint.  The j-pipe is already showing rust though.  I
sure hope some one makes this in stainless soon.

Fuel Injection:
I sent the computer to Darrell during the winter and had him install a
Digitool connection and make me a tool.  I also purchased new injector seals
& fuel hose kit from Ken.

Getting it going:
The first day I drove it, I had trouble starting it when it was hot.  It
turned over very slowly like the timing was too far advanced.  I reset the
timing and still had the problem.  I figured the rebuilt starter was bad, so
I put the old one back in.  Then I realized that the alternator wasn't
charging properly (Digitool).  So, I finally figured that the slow turning
when hot situation was a low battery that was surface charging it self as
the engine was cooling off.  I put in an alternator from a parts car and
everything was fine.  I stopped for gas in Eastern PA and the starter
wouldn't work.  I had to catch it in gear all the way home.  So, I put the
rebuilt starter back in after I got home.

What are my opinions:

Engines - no question - get your rebuild from Boston Bob

Stebro Muffler - nice fit, includes tail pipe & brackets, a slight bit
louder, but I can barely notice from                                the
drivers seat.  if you have rusted brackets & straps, it is actually less
                           expensive than others.

Stainless head pipes - Real nice. Flanges don't line up 100%, but not bad

Digitool - A must.  I know my temp 1, temp 2, afm, etc. are all ok.  The new
O2 sensor may not be.

Parts :
        Boston Bob - doesn't let you know often, but he has good parts &
some pretty good prices
        Bus Depot - Great new catalog, good parts, good prices.  I hope ship
time can improve.
        Ken Wilford - good parts, prices, & service.  Real friendly too.

Well, I just remembered this is an E-mail, not a book.

Walt Spak
Pittsburgh, PA.
wnsopc3@3rdm.net