The two stud bolts on my 1984 1.9L engine holding on the alternator bracket
have broken off for the third time in less than the miles between oil
changes.

First the bracket itself broke (and was replaced by previous owner at least
twice) and I replaced it. Then the studs (brand new from VW) broke 1,000
miles later.

The mechanic (reputable, recommended here) had drilled out the studs last
time and replaced them with Audi exhaust bolts ("strongest available"). In
doing so, he first cut across the motor sideways to try and twist the broken
studs out, leaving a huge, thick, deep cut in the housing where the
alternator studs thread into the engine.

Now, less than 500 miles later, the right bolt has snapped off, and the left
bolt is sitting in an elongated hole nearly twice the size of the stud with
no threads to screw into. I assume this is because he couldn't drill
straight in and had to drill in from the side a bit.

1) Did I get ripped off by this mechanic? Did the cuts weaken the metal?

2) How can I fix this? Drill out the left stud and helicoil it for a new
stud, Get the right stud out and replace it, sure. But won't the cut-away
metal be so weak the new studs will just tear out again?

3) How can I "fill in" the metal to make a nice strong area surrounding the
stud hole?

4) How common is this on the 1.9L? Is something wrong with my engine,
vibrating too much? What can I check?

5) How can I better brace the alternator to keep this from happening again?
The mechanic is talking about building a bracket, maybe across the top of
the engine to brace the alternator, or putting in a 65watt Jetta alternator,
which is smaller and lighter. Both make me nervous: jerry-rigged fixes.

All help appreciated. Please reply P-MAIL as I'm off the list right now.

Steve
Seattle, WA

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