This is not a fun job. The studs are a really tight fit and they are a
grade 10.9 stud which makes them hard to drill. You will probably need
good drill bits, a right angle drill, variable speed, EZ outs and a
torch, (oxy/acetylene).  If you do have to completely drill out the
studs to the threads, you will need a heli-coil. High strength is needed
here. There is not enough material in the case for oversized studs or
solid inserts. As for how deep to drill, start with a small drill and
you will feel where the stud ends. Replacement hardware here must be at
least grade 10.9 including the washers. The wrong nuts are what probably
cuased the failure in the first place. Check the bracket carefully.
These are also prone to cracking.

Dennis

-----Original Message-----
From: Vanagon Mailing List [mailto:vanagon@gerry.vanagon.com] On Behalf
Of Paul Guzyk
Sent: Thursday, February 10, 2005 8:47 PM
To: vanagon@GERRY.VANAGON.COM
Subject: Broken bolts on 1.9L lower alternator bracket....

On my 84 Vanagon the two studs that hold the lower alternator bracket
to the engine block have broken off (see Bentley page 27.15)

....and of course they've broken off behind the bracket aka inside
the engine block.  :(

In order to get access to the holes in the block I removed the
alternator, the metal coolant cross pipe from water pump housing to
the passenger side head then I removed the oil filler tube from the
bottom of the block.  (The oil filler tube is held on by two 13mm
nuts, one easy to get at, one not so easy).

Tomorrow I intend to drill out the two broken studs then re-tap them
with the standard 8mm threads.

How far into the block can I drill?
If I go too far I assume I will break the water jacket?   That
wouldn't be fun...

Anyone have a better solution?

If you've rigged up some other way to hold the lower alt bracket
please post photos....

-Paul