Here is my contribution for an 87 waterboxer:

242000 kms and counting (with original heads, gaskets, etc.)

some repairs needed:
3 times bars leak after coolant changes (no noticeable temperature changes)
plastic coolant manifold cracked
coolant pipe (left) developed pinhole (made a nice steam cloud behind the
car, like an F1 or Cart engine blowing up, however I was able to continue
for a couple of kms, the coolant sprayed on the exhaust pipe)
complete new (custom) exhaust system (2 cats incl. O2 sensor, 3 mufflers)
cracked expansion tank
cracked coolant level sensor
some electrical problems with distributor
replaced the "famous" blue sensor this year

maintenance:
new oil every 5000kms
new airfilter every 10000kms
new spark plugs every 15-20000kms
new coolant about every 3 years

comments:
At about 120000kms the head gaskets began to drip. Bars Leak has certainly
been cheaper so far than a head job despite the fact that there are better
sealants.
I still think that there are better VW engines and I find the concept of the
waterboxer great however I do not like some of the engineering,
therefore I am looking for a TDI engine which has the same power, much
better torque which is important for off road travel and much better fuel
consumption.

 
Bj�rn Ratjen

1987 Syncro Est Alia (self camperized)
1995 Passat TD
(1982 Vanagon Diesel)
1979 VW Bus (self- camperized)