Date:         Sat, 20 Sep 2003 09:31:38 -0700
Reply-To:     mark drillock <drillock@EARTHLINK.NET>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         mark drillock <drillock@EARTHLINK.NET>
Subject:      Re: Diesel head gasket blown?
Content-Type: text/plain; charset=us-ascii

As Tim says, leave the manifolds in place though that makes the need for
alignment pins even more critical. You can make 2 alignment pins from
the old head bolts. I cut the heads off and cut a screwdriver slot in
the ends with a Dremel cutting disc. Screw these into diagonal corner
holes just a few threads and then they will stick up far enough for easy
removal. I use a vacuum cleaner with a soda straw on the end to clear
out the bolt holes. Compressed air can make a mess. To keep coolant and
oil out of the vacuum, I make a fluid separator for the vacuum out of a
16 ounce clear plastic drink bottle. Duct tape the neck of the bottle to
the end of the hose. Poke a small hole in the bottom of the bottle and
insert the soda straw. The fluids will be then caught in the bottle.

The exhaust flange gasket is common to other diesels VWs from that era
such as Dashers. I have no problem buying them from the dealer or other
VW specialty parts houses. VW part # 811 253 115 A. Only a few dollars
from online parts houses such as:

importedcarparts.com    H4000-24207 Dasher Diesel Exhaust Gasket $1.51

Mark

Doktor Tim wrote:
>
> At 11:05 PM 09/19/2003, you wrote:
>
> >As to the head gasket.  Having someone else do it might be expensive.  Not
> >because it is difficult but because taking off all of the manifolds are
> >time consuming.
>
> This procedure does not call for nor require removal of the manifolds. Just
> remove the air filter housing top and exhaust pipe.
....
> Use a turkey baster with piece of hose to remove all the coolant from the
> block. You simply must have compressed air to clean the bolt threads
> effectively, and coolant will get blown everywhere if not removed.
>
>...
> You must have pins to place in 2 bolt holes to set the head and gasket in
> place, then start the other bolts, then fish out the pins with a magnet and
> put in those bolts. I have pins for the 11mm head bolts if someone needs them.
>
> With the head off, inspect the threads for the exhaust pipe mount. If they
> are still in good order, set studs here for mounting with nuts. Make a new
> gasket by hand from exhaust material. At least I have never been able to
> find this one.
> ...