Project Background

This will be a history of my project to convert our Vanagon from its stock engine to a new (used) Ford Zetec four-cylinder in-line engine.  Why?  Well, my association with Volkswagen's water-cooled engines consists of three efforts:  a 1980 Volvo diesel engine (by VW/Audi), a 1982 VW Rabbit convertible, and this 1990 Vanagon.  The diesel cooling was acceptable - it just leaked oil.  The Rabbit was a Rube Goldberg nest of hoses, pipes and several dozen joints that constantly loosened, cracked, and leaked coolant.  A friend of mine once identified the year of my Rabbit, in the dark, by the smell of hot coolant that always surrounded it when parked.  The Vanagon?  It's barfed out its water jacket gaskets three times.  First time, replaced under warranty.  Second time, some pity, but they only paid for parts.  Third time, we paid the whole thing.  This job, not done by the dealer, seemed to last - over ten years so far - but when I saw the green puddle on the floor a few months ago, and added the cost of a complete new exhaust system that it would need to pass inspection, the hunt was on for an alternative.