First things first, there is a big difference between importing a vehicle
from Canada and importing one from elsewhere (i.e., Europe).  If the
Canadian vehicle was originally built for the Canadian market it shouldn't
be too difficult or too expensive to import into the USA since Canadian
vehicles are basically the same as the US models.

The fun really starts when you bring in a non-Canadian vehicle (DOT term,
not mine).

Here's the basic procedure for non-Canadian importation (not detailed):

1 - The RI is the only one who can legally pick up the vehicle at the port
of entry.

2 - The RI transports the vehicle to his facility and performs all
conversions necessary to bring the vehicle up to US DOT standards.

3 - The RI documents everything: all the conversions and everything DOT
related that didn't need to be converted.  Approximately 200 photos are
submitted to the DOT along with explanations of everything converted and
why.

4 - The RI now transports the vehicle to the EPA testing facility for the
infamous emissions bag test.  At the laboratory, the vehicle has to sit
overnight in the lab prior to testing.  The test is performed on a dyno by
simulating a "normal" driving day.  All the emissions are captured in a bag
for emissions analyses.  BTW: this test alone costs ~$1700.

5 - The RI obtains a recall insurance policy on the vehicle and submits all
the documentation to the DOT.  Within 30 days of submission, the DOT usually
issues a certificate of conformance and the RI releases the vehicle to the
owner.

6 - The owner (sometimes the RI) takes the vehicle to their local DMV for
registration.

7 - Done.

Things get a little more complicated if this is the first time a vehicle of
that year/model has been imported (for Vanagons the only previously LEGALLY
imported years have been '80, '88, '89 & '90).  For vehicles that fall into
this catagory, the RI must petition the DOT that the vehicle is capable of
being modified to meet DOT standards.  This process usually takes between 4
& 12 months.  It doesn't really add much in the way of cost, other than
storage fees while waiting for the DOT to appove the petition.

Cheers,

Jeff
www.vanagonparts.com