Date: Sun, 25 Jun 2000 21:29:44 -0400
Reply-To: Walt Spak <wnsopc3@3rdm.net>
Sender: Vanagon Mailing List <vanagon@gerry.vanagon.com>
From: Walt Spak <wnsopc3@3rdm.net>
Subject: My 91 GL tale (long), or what ever happened to this Vanagon
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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
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