The bolt holding the alternator on (the one that screws into the block, looks to be a 3/8 bolt) broke off about flush with the block, all on it's own. Is this a common occurance? A couple of years ago the bracket on the other side of the alternator broke in half, again, all on it's on. Anyone know what might be happening here, and the best way to get the bolt drilled out of the block? There's sure not much room to maneuver in there.
dhughes

I never heard of either of those problems happening. Drilling/tapping or drilling/helicoil is really about your only options.

Thanks for your quick reply. I've got an ease- out set, but it looks like it's going to be a problem getting a straight shot at drilling it, even with an angle drillmotor.

man feel sorry for you, that place is super tight to work.

you can loose engine mounts up, then try to jack engine up, high enought to work there.

had problem with same bolt when i was installing CL-S camshafts, thread in engine block was shorter than bolt, it was tough to get bolt out plus had to rethread hole in engine block and on bolt.

How much can you jack the engine up without disconnecting a lot of other stuff? I had thought of possibly taking some of the things off the wheel well panel and cutting a hole big enough to work through. Do you think that might work?

drilling might be difficult, you will be drilling throgh frame member and that thing is about 2"x3" square tube.

as far of lifting:
disconnect wiring on passenger side of engine, remove bolts which holding AC piping, remove nuts on top of front and rear engine mounts, remove two bolt which connect engine to engine mount on passenger side, now you can lift engine 2"-3". you probably go higher but you need to watch exhaust.

I see what you're talking about. That does look like the best way to go. Thanks a lot.

Everything going ok til I tried to remove the belt tension pulley/bracket. I removed the 2 bolts and pried as hard as I dared, for fear of breaking something, but it didn't budge. What am I missing?

Disregard previous question. There's a small bolt through the center.

are talking about AC/Alternator belt tensioner or timing belt tensioner?
And why are you taking tensioner off? it didn't give me any problem when i was working on my alternator.

The AC/alternator tensioner. I couldn't get a straight shot to drill out the bolt with the tensioner still on. I couldn't get the bolt out with the ease- out, so I wound up drilling all the way through and putting a 4" 3/8 bolt in with a nut on the back side. Luckily the way the block was made let me do that.

:thumbsup:

I know I am replying to a seven year old thread. For future readers with the same problem I want to confirm that the method described previously in the thread works perfectly. Remove the center 17mm nuts on the front and rear motor mounts, remove the two 15 mm bolts on the passenger side. I was then able to jack the engine up 2 inches giving me room to drill out the broken lower alternator bolt. I also removed the tensioner pulley to make room my drill. The bolt that goes through the center of the pulley is left hand thread meaning you turn clockwise to loosen it. Thanks to those who left the information originally. A daunting task was made much easier.