On Mon, 13 Dec 2004 22:49:44 -0800, David Marshall
<mailinglist@fastforward.ca> wrote:
> The 2.0L block is 16.5mm taller, so I think there will be a few dimensional
> differences to overcome.
>
> David Marshall

David,

The bracketry I refer to is what is used to secure the accessories
such as the alternator, PS pump, and AC compressor. There are no
dimensional differences in this area. There are 4 studs screwed in to
the block for the cast aluminum bracket. Three are a perfect match to
the 1.8 block. The 4th studs is supposed to screw into a threaded boss
on the block. This is missing on the 1.8 block. The cast iron mount
used on the 1.8's utilize a separate cast iron or steel bracket which
is attached via a bolt through the timing belt cover and through the
lower alternator mount. That is not used on the 2.0 block at all.

At any rate, the problem can be solved by drilling an tapping a hole
where the stud with a hex extension can be installed. Either that or
make a flat steel bracket with two holes. One hole can then be bolted
to the original mount where the 4th bolt goes in on the 1.8 block. The
second hole can be threaded or supplied with a nut to match the 4th
bolt which is used to secure the cast aluminum A3 bracket. There is of
course the possibility of just leaving the 4th mounting point out.
That is apparently what some of Chris DeLong's customers have been
opting w/o any failures thus far.