Ah Stainless studs!! There's the problem. Stainless hardware is not strong.
Most only rates as a grade 5.8 on the metric bolt strength scale. There are
some grades that are stronger but this is definitely the wrong application.
Keep stainless for exhaust, valve covers etc. Not for anything that needs
strength. Get the holes repaired, use heli-coils if needed and use bolts
that are at least grade 10.9 or 12.9. Make sure the mounting surface on the
case is straight. Also make sure any washers used are heat treated, avoid
lock washers. Cheap washers will deform causing the mount to loosen leading
to another set of broken bolts.

Dennis

-----Original Message-----
From: Vanagon Mailing List [mailto:vanagon@gerry.vanagon.com]On Behalf
Of Steve Sullivan
Sent: Sunday, September 09, 2001 2:18 PM
To: vanagon@GERRY.VANAGON.COM
Subject: HELP! Another Broken Alternator Mount

Hey y'all, been lurking on the digest lately.

My alternator mount has broken for the forth time in less than a year,
today. I've got the 1.9 leaker and the bolts/studs holding the alternator
mounting bracket to the engine block keep breaking. The last time, a
"mechanic" screwed up removing the broken studs, leading to an unneeded
$1000 engine rebuild. Now, less than 3,000 miles since the reputable rebuild
shop welded the holes shut, and drilled new holes, the bolts have sheared
off again.

I even added the 2.1L extra brace to help, it snapped too.  The only thing
holding my alternator to the motor for who knows how long is the adjustment
bracket.

Does anyone know how I can prevent this from happening every three months?
Are other 1.9l folk having the same problem? I'm even using extra-strong
stainless studs, they just snap off. Do I have some kind of awful engine
vibration? How could I fix that?

Help, I can't keep fixing this every time I change my  oil!!

Many thanks,

Steve

Steve Sullivan
Off the Map Consulting
1326 S. 13th St.
Mount Vernon, WA 98274
360-428-7018
steveis@speakeasy.org