Pulley broke off engine block

Westwood

Guys
Left my car in for a snapped fan belt, all was good until mechanic went to take off pulley and the bracket fell apart, as seen pretty rusty. It's an 08 vauxhall astra diesel, the bracket is basically part of the engine block and he says the engine would have to come out to replace due to its location and he wouldn't do it either as he reckons a weld would again brake and a new engine is prohibitive considering the age..
The car is great in every other aspect and I'm reluctant to scrap it.
Pics attached.
Any options appreciated or companies who would get this sorted?
Many thanks in advance.

SCOOP 64

just wondered why he was taking it off, it looks like spring pulley which you pull back to release tension to take belt off unless it snapped on pulling it back to put new belt on.

Neilw

The threads look clean on it, no rust so I doubt it was seized.
I wonder was it over tightened when refitting and it cracked the bracket off the block.

gctest50

4th pic - bolt was loose for the last while and weaked the bracket (made of some form of chocolate)

you can see where the anti-rotation pin on the tensioner has made bits of its locating hole

Westwood

Thanks for looking and feedback. The worn pin makes sense as you can see a little crack on the far side of plate also. So what's the consenses here any hope of getting this fixed? Anyone know of somebody... Very much appreciated thanks

mickdw

Just had a look at a diagram of belt run.
If it was to be the difference between having to scrap the car or not, you could try to eliminate the tensioner, find a shorter belt and make a slightly different alternator bracket that would allow belt to be tensioned old style.

gctest50

Westwood wrote: »

Thanks for looking and feedback. The worn pin makes sense as you can see a little crack on the far side of plate also. So what's the consenses here any hope of getting this fixed? Anyone know of somebody... Very much appreciated thanks

Take off the aluminium bracket on the left and cut back the broken iron bracket

Then make an L-shaped bracket to slip under the bolts of the aluminium bracket ( on the left, first pic )

Hellrazer

mickdw wrote: »

Just had a look at a diagram of belt run.
If it was to be the difference between having to scrap the car or not, you could try to eliminate the tensioner, find a shorter belt and make a slightly different alternator bracket that would allow belt to be tensioned old style.

This is probably the cheapest and easiest fix.
Get a smaller belt and I reckon the adjustable alternator bracket off the old Transit 2.5 diesel would do the job with minimal modifications. Youd just need to mount the alternator in such a way that it can be adjusted manually.
That bracket part number 6518344 has saved my ass a few times when a self adjusting tensioner has given up.