Date:         Mon, 15 Jan 2007 23:09:26 EST
Reply-To:     DanielCRoberts@AOL.COM
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         -- Dan Roberts <DanielCRoberts@AOL.COM>
Subject:      Boston Bob engines - Use caution
Content-Type: text/plain; charset="ISO-8859-1"

I relied on recommendations from this List and chose Boston Bob when I needed 
a rebuilt engine. Unfortunately, the results were disappointing.  

The Boston Bob rebuilt engine was installed in my 89 Camper GL (2.1 Liter) 
last spring. Almost from the beginning I noticed oil leakage from the oil drain 
plug and from the front and rear of the engine. The leakage was disappointing 
but at least did not seem to be severe when I left for an extended trip to 
southeastern US. 

Prior to the trip, I talked with Bob McDonalds (Boston Bob) and he assured me 
the leaks would probably dissipate over time as internal engine pressure 
lessened with engine wear. However, when I returned from my trip, my own mechanic 
examined my engine and showed me that both front and rear main seals had 
substantial leaks, as did the oil plug. 

I contacted Bob McDonalds again. He again suggested the problem might be with 
internal pressure related either to tight piston rings or to a collapsed 
engine gases recirculation tube (his speculation). He eventually sent a new rubber 
tube although my mechanic had assured him and me that the existing tube was 
OK. I installed the new tube anyway. He also sent several different oil drain 
plugs and several different oil drain plug rings. 

None of the drain plugs or drain plug rings stopped the oil leakage from the 
oil drain plug. The oil drain plug still leaked, as did the front and rear 
main seals. 

I sent an email to Bob asking him to provide some compensation for the oil 
leaks and their effect on the value of my Vanagon. He did not respond to my 
email. 

Next, while traveling in Colorado, the engine overheated when the alternator 
froze, breaking the belt that also supplies the water pump. I pulled off the 
road and turned off the engine as soon as the coolant trouble light came on. 
(However, the alternator trouble light had come on about one minute earlier and 
I did not pull over and stop as soon as that light came on.)

I examined the engine and saw what appeared to be a blown front main seal. A 
subsequent examination of the engine by a 30-year Vanagon mechanic in Colorado 
confirmed my suspicion. Of course some would argue the fault was mine for not 
immediately turning off the engine when the alternator light came on. 
However, a subsequent investigation by the Colorado mechanic revealed that both front 
and rear main seals (head gaskets) had been improperly installed. 

Both front and rear main gaskets had a large amount of glue over the entire 
inside grooves--facing the engine. As a result, when the glue had dried, gaps 
were created, thereby allowing oil to push through the gaps. The Colorado 
mechanic said that the gasket failure was inevitable, given the way the gaskets 
were installed. 

Boston Bob has refused to respond to my subsequent emails in which I asked 
him to take responsibility for the leaking oil and subsequent blown gasket. 

Replacing the improperly installed seals cost me about $1,500. Of course this 
does not include the motel bills when I was stranded in Colorado for 12 days. 
Fortunately, I can say the front and rear seals no longer leak after being 
properly installed. The oil plug still leaks. 

This situation has been disheartening, as well as costly. I had been pleased 
to obtain a Boston Bob engine. I thought I was dealing with a reputable 
mechanic. Unfortunately, Boston Bob has refused to stand behind his product even 
though I can document and prove the engine was rebuilt with a substantial error. 

Because of the error and because of Boston Bob's refusal to be responsible 
for the error, I suggest other List members use caution when considering whether 
to purchase a rebuilt engine from Boston Bob. 

Dan Roberts

CC: Bob McDonalds