D5254T advice needed on changing the idler bracket

[bertuk]

hi anyone have an idea how easy is it to change the main cast alloy bracket part number 9180595 this also holds the power steering pump,alternator,and aircon motor, on a 1996 850 tdi 5 cylinder the trouble is i put in a new fan belt idler and over tightened and stripped the thread in the bracket, so now ive got the nightmare scenario of removing the bracket how easy are they to remove ?has anyone done one before help would be much appreciated

[bertuk]

no diesel boffins on here ? looks like im diving in at the deep end then, starting tomorrow

[Ian HT]

Although I have got a 1999 TDI V70 I have no experience of the part you refer to. However, my first thought on a stripped thread is - Have you considered a Helicoil? I borrowed what I needed (for a different part on an Austin Healey) from an engineering shop and paid only for the bits used. Dril then tap the stripped thread out oversize and fit a Helicoil (a specially profiled spring that screws into the oversized thread to bring it back to standard size).
In some cases it may be possible without dismantling - may need a right-angle adaptor on an electric drill... If the part comes off you may be able to repair the original "on the bench".
I believe that in an aluminium casting it is supposd to be stronger than a normal thread and so is sometimes done as a precautionary measure to avoid the problem occurring in the first place.
Hope it works out,
Ian

[bertuk]

hi ian if i could get the main bracket out i could have had it done, but when its in situ on the engine theres no chance of doing it,ive scoured the internet for a diagramme of how to remove the alternator and aircon unit,but found zilch no one seems to know its like a taboo subject,i even went on the audi forums, nothing their either