Ben, using the wrong starter would definitely be a problem! :-)
The original waterboxer upper starter/tranny bolt will fit into a recess of
the adaptor, no clearance issue or special bolt needed.

If you still have the tip sheet sent with the adaptor, it should clearly
state that the wire end may need replacement. Quality crimp terminal will
function just fine. Why VW used such a thick terminal end on the Vanagon
charge wire is baffling. I usually swap in a 6-gauge replacement cable
anyway, as the stock cable is too small for the additional alternator
power-draw that most of us add.

Karl
www.westyventures.com

On Sun, 15 Apr 2012 13:29:47 -0700, BenT Syncro <syncro@GMAIL.COM> wrote:

>The incorrect starter identified above are for a 2004-later manual trans
TDI. The correct one is from a 1996-2003 manual trans TDI.
>
>There is a slight difference in length. But the problem is the bolt
patterns are not the same. As luck would have it, the  letter 'M' was badly
scratched up on the starter I got. I am not sure about the significance of
the 'R'. Without that 'M' and a vendor swearing it was for an '03 TDI, I
spun my wheels trying to figure out why it would not fit. It's clear now.
>
>So we start bolting everything up today. Then [B00M!] another snag. The
fellow who worked on the starter last time, substituted a hex head for the
upper bolt. The head would not clear. Now I have to hunt down a hex head
bolt longer than a cigar -- on Sunday!
>
>Also noted that the connector on the main harness on the Vanagon is
designed for a very long stud on the original Vanagon starter. Guess this
means some cutting and crimping will be in order. I dread replacing it with
a less sturdy terminal end but cannot see any way to connect to the shorter
TDI terminal stud.
>
>Foiled again. Getting back to this tomorrow or the next.:-(