Rob,

If you look here you will see my Alternator bracket mod:

http://i16.photobucket.com/albums/b7/misterpolak/WBX_transplant/Bothengines.jpg

If you look I have two tension brackets - one tensions and the other adds
support to the alternator base bracket.  I think the reason why so many 1.9L
studs break is because that very bracket is missing.  I came up with the
idea then I noticed that 2.1L engines already have that upgrade.

So... my base alternator bracket has the outside stud missing.  I've
installed a good bracket and the additional tension bracket along with a
longer carriage bolt that holds the alternator and have not had any
problems.

I would recommend any 1.9 WBX owner to do the bracket retrofit now.

Chris S.

On Mon, Jul 28, 2008 at 5:37 PM, Rob <becida@comcast.net> wrote:

> The 1.9 VW waterboxer in my '84 westy has the studs/bolts that hold
> the alternator bracket broken off.
>
> I found this problem in Weed, CA as we were moseying on our way back
> to Washington in our first big trip in this Westy. The alt belt also
> drives the water pump.... I used safety wire (mechanics wire) to hold
> the alternator bracket so I could get tension on the belt and drive
> the water pump. We came straight home after that. I promised the VW
> back in Weed that I would not drive it any more if it made it home
> for us (490 miles). It made it and I kept my promise.
>
> This long block was put in by the PO around 30k miles ago. I'm
> pulling the engine anyway to put in a Subie and would like to fix
> these studs so I can sell the 1.9 .
>
> I just looked at the engine and then took a look at the Bentley,
> those studs are in the case half and one of them might have been
> 'fixed' before. One is broken flush and the other is broken off
> inside a little. There is a really small hole drilled above one of
> the studs, like a way to get penetrating fluid on to the threads.
>
> Any advice on replacing these studs would be gratefully accepted, I
> really don't want to trash the case...
>
>
>
>
> Rob
> becida@comcast.net
> In western WA with a broken '84 Westy and half a summer left.
>