AC Delete 944S - problem
 

I have the compressor out, the alternator off, and three of the four bolts off of the stock alternator bracket (intend to replace with the AC delete bracket).

The last bolt will not come out without removing the intake. I really don't want to pull off the intake. If I do it's not only a major pain in the ass but I would need to order a new gasket, etc. When it comes to the major bits on the engine like this I really do not want to take it off for fear I'm going to F something up.

Here's a pic; you can see the intake above, the bolt butting up against it, and the bracket below.

http://i15.photobucket.com/albums/a3...bb/photo-1.jpg

Is this problem specific to the 16V 2.5L? I haven't found any reference to this problem anywhere else... seems significant enough to mention.

I'm thinking about using a dremel to cut off the head of the bolt, remove the bracket, and then back the bolt out. I'll probably have to cut it off again, and again, iteratively, in order to get this thing out. As you can see I suspect this bolt is as long as the other top bolt (see below). Is this nuts? Once I start cutting... obviously there is no turning back (except for taking off the intake). Seems like it it is going to take me a year and 70 cutting discs to get through this grade 8 bolt in a place where I can't even see what I am cutting (in addition to scattering tiny metal bits all over the engine).

http://i15.photobucket.com/albums/a3...bbb/photo1.jpg

Ok, got the bolt out and the stock bracket off. Took some choice curse words and a lot of trial and error.

The bolt is long but this is misleading as the bracket is thick so you only need to back it out a few more turns past the stopping point when the bolt impacts the bottom of the intake manifold. I figured this out by taking measurements of where the other long top bolt came free of the threads and comparing. Plus also feeling the bolt start to loosen like they do when they are ever so close to coming free.

I couldn't get the bolt head off with a dremel (cuting disc won't fit in there) or hacksaw (too little room and not enough patience) so I started grinding down the square corners on the top of the bolt. This works because the bolt is on an angle, and it's just a small amount of metal (relatively speaking) touching the manifold and preventing you from making a few more turns to back out the bolt. After enough material gets removed on each point you can spin the bolt a few more times and work the whole thing out.

Here's a pic of the carnage. Hope this helps somebody down the road if they encounter this fun situation themselves.

http://i15.photobucket.com/albums/a3.../bbb/photo.jpg

why didnt you just remove the ac and use a shorter belt.

Because he wanted a proper alt delete bracket and adjuster?