While installing a new oil temp sender, I stripped the threads that that
hold one of the two bolts that hold the sump plate.  The other one is ok,
but now the plate leaks oil like sieve.  Are the threads directly in the
block?
>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>
Yes.
>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>
Do I have any alternative other than to drill the hole out and tap it to
the next metric thread size?
>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>
Yes, Garland, you always have alternatives; it's the consequences that must
be weighed. If you are cavalier, tap it and use a Heli-Coil insert and some
Loctite (also spelled: Lactate, Locate, Locative, and Locket). You may not
need to drill it. Check the Heli-Coil chart. It seems to me that HeliCoil
has inserts that only require tapping, no drilling. If you are anal (like
this writer), take (tow) the van to a competent VW machinist and have him
weld/drill/tap (what ever) to make it right. Could be a bummer if that sump
plate let loose in the middle of "Write Your Manifesto Here", Montana, or
Downtown Washington, DC.

G. Matthew Bulley
Principal
Bulley-Hewlett & Associates
Communications for Organizational Development
www.bulley-hewlett.com
(888) 468-4880 toll free