Hi, I just got my 2004 Starex Van TDIC, and found out the next morning battery was dead, I ask a friend to tow me to the nearest battery shop to check my "almost" new battery, and found out that my alternator was hanging without the tensioner bolt.
The culprit was the aluminum oil cooler bracket hole that hold the alternator was already loose( to big and oval) it went a lot of work to my friend shop to remove the darn thing. Almost made total overhaul to the engine to remove/ replace the aluminum oil pump bracket. And guess what ?a new replacement isn't cheap either,
What seems to be the problem is that the hole is all aluminum, it doesn't have a bushing or any sort to prevent it from getting bigger, And I don't tend to buy one since it's too expensive,
So what I did start using my shop trusty Tig/ Aluminum to build up the large hole, inserted aluminum square rods and build up the bracket hole, and inserted a 1/2 dia bushing. that has a 3/8 i.d. : And guess what? it's better than buying a new one, and saves me worry free driving in the future. (IMG:style_emoticons/default/thumbsup.gif)

Way to go. Good for you.

Thanks Bro! by the way other things to look out for regarding this model in case of breakdown??

another method i've used on stripped aluminum threads is to use a steel threaded insert like Heli Coil or Timesert.
Saves having to remove the item for welding which puts a lot of heat on the aluminum part and increases the risk of distortion.

I guess that's one time saving procedure, I'll try to look at that type of repair you made and use it in the future. (IMG:style_emoticons/default/liebe011.gif)