I agree with Dennis.  Although I haven't yet had this particular problem,
I've had a similar situation regarding exhaust port studs/bolts/holes being
stripped.  I'm not a fan of the common helicoil in these critical areas, so
I have a suggestion that worked for me.  Use Timeserts instead for a beefier
"helicoil" - these are actually a threaded bushing.  Since being introduced
to Timeserts in the late 70s, I've rarely used helicoils anymore.  They come
as a kit with bushings and the proper tapping tools to do the job.

Timesert was originally located in Rosemead, CA, just a few miles from where
I grew up and "cut my teeth" on similar Air Cooled VW engine problems such
as this.  They're located up near Reno, NV and can be reached at:

http://www.timesert.com/

Jim Thompson
84 Westfalia 2.1 "Ole Putt"
oldvolkshome@earthlink.net
jim@karmannghia.com
http://www.oldvolkshome.com
***********************
----- Original Message -----
From: "Dennis Haynes" <dhaynes@OPTONLINE.NET>
To: <vanagon@GERRY.VANAGON.COM>
Sent: Thursday, February 10, 2005 7:34 PM
Subject: Re: Broken bolts on 1.9L lower alternator bracket....

> 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