Back when I used to work on lots of VW diesel engines, I made a quick n'
dirty thread chaser from an old head bolt.  Just grind a long shallow vee
vertically along the threads to allow junk to accumulate as you thread it in
and out of each bolt hole.

On 9/17/07, Mark Drillock <mdrillock@cox.net> wrote:
>
> The bolt hole cleaning is even more of an issue in the Vanagon because
> of the leaned over angle of the diesel engine in the vans. The coolant
> can easily fill the lower bolt holes as the head is removed. The angle
> makes it harder to see the lower holes and how much stuff is in them.
> The main threat is that when the bolts go back in they will get tight
> against the stuff in the bottom of the hole before they pull the head
> down tight. The head gasket can leak and the block can crack at the
> hole. The torque on the diesel head bolts is high.
>
> I use a vacuum cleaner with a soda straw to clean out the holes.
>
> Mark
>
>
>
> neil N wrote:
>
> > Interesting to hear of the bolt hole cleaning.
> >
> > I remember replacing the head on my Rabbit 1.6 NA (1.5? can't
> remember....)
> >
> > After I did the job, it worked fine. Car had a new rad, water pump
> > etc. etc.  I sold it to a friends kid, but since I'd never replaced a
> > diesel head before, the price was *very* fair.
> >
> > The kid, car and I went to a VW dealership to have my work checked
> > out. (he knew the mechanic). The mechanic asked if I had cleanded the
> > bolt holes. "uh, no". I didn't even think that IF there was a little
> > oil or whatever in a hole that the head bolt would create a LOT of
> > pressure. Add heat to that, and whamo. Possibly a crack.
> >
> > Neil.
> >
> >
> >
> > On 9/17/07, Mark Drillock <mdrillock@cox.net> wrote:
> >
> >>You should join the diesel Vanagon list for this project.
> >>
> >>http://autos.groups.yahoo.com/group/Diesel-Vanagon/
> >>.........
> >>
> >>Cleaning out the headbolt holes in the block very well before putting in
> >>the new gasket is CRITICAL.
> >>
>