I know nothing about doing this - what should I expect? I suspect others have done this - so please feel free to simply point me to a link where it's discussed (my googlefoo is terrible)

 

Suspect the worst. What engine, and for what?

 

200 and 300tdi's can be had without personal import dealings(already here). if td5 is what you want, I'd suggest import to neighboring country dress it up like a fat little person and go "weekend at bernies" style across the border

 

I was looking into importing similar things and the basic understanding I got from my research is the only thing the NHTA or DOT or EPA care about are whole vehicles (older than 25 years anyways)...you can import an engine in itself because it's not attached to a vehicle.

However using that engine on the road is still a nono in most states and I cant think of a state that would allow you to operate any vehicle with a mismatched engine type (ie was gas now diesel) without going through a long expensive process with the EPA. Though as dusty said, the 200 and 300tdi is already registered with the EPA so you may not have to go that far.

People have before taken engines out of whole vehicles and shipped them separately directly to the US but if they find out don't expect to get it from customs (or a refund)

 

State to state laws are different. If it's pre OBD2(95&prior) in VT you just reregister it with less cylinders and a different fuel type

 

You can import a full vehicle pre 1989 with no issues. Find an old refurb mil surplus D90 or D110 wagon with a td5 in it for like $20k after conversion and enjoy the rest of your life being awesome.

 

Has to be original engine though, you can't bring an 89 in with a Td5.

 

Truth! I meant to specify. I've seen "exporters" of those vehicles that do those modifications though I suspect that is only to countries that accept it. I'd still rather have a 300tdi anyways since it's all mechanical vs the computerized td5.

 

Not just original engine. LRNA is helping customs prevent any updates. For instance, replace the old style two piece sliding window doors with the new one piece crank window doors and there's a good chance it'll get seized. There are hundreds of similar things they look for.
To be safe, you want a completely unmolested vehicle.

 

I know

I was just mentioning it so he didn't get any ideas.

Don't forget updated seatbelts...