John,

I had a similar situation and was able to modify the mount, eg drill out
and use a stud with bolts on each end to take the place of one of the
allen heads that hold the compressor to the mount. I was able to do this
without removing the mount too. Lemme see if i can take a shot of what I
did as an image is a lot easier than explaining it.

As far as removing the AC mount, yes the manifold needs to be loosened
and pulled partially to the side to get to, at least one of the mount
hold downs to the case.

-john

On 7/8/2011 2:06 PM, John Rodgers wrote:
>  At some time someone really buggered up the two holes in the cast
> aluminum AC compressor mount on my van. One hole is threaded directly
> into the aluminum boss in the casting, and the other side has a threaded
> steel bushing pressed in. The threads in both sides are toast. Anyone
> have any suggestions as to how to repair this?  I would like to stay
> with the size bolt specified in the ETKA.  Allen Key Head Bolt - N
> 019-929-1.  If I have to drillout and re-thread, then I need bigger
> bolts, and that would require I  also drill out the mount holes in the
> AC compressor. Don't want to do that. Compressors often must be
> replaced, and I don't want jury-rigging just to make something work.
> Next time around things don't fit together properly!
>
> I may have to take this to the machine shop for the proper repair. If
> they have to be drilled out and rethreaded, I will want the machine shop
> to re-bush both sides with bushings of the correct bolt size, even
> though only one side currently has a bushing.
>
> Can the AC mount be removed without having to loosen or remove part of
> the intake manifold?
>
> Thanks,
>
> John
>
>
> --
> John Rodgers
> Clayartist and Moldmaker
> 88'GL VW Bus Driver
> Chelsea, AL
> Http://www.moldhaus.com