During my attempt to replace the tensioner pulley on my 997.1 C2S I managed to royally screw up a simple job, and use the clothes and of the ranch rather than the open end. I am unable to remove the bolt and the wrench from the tensioner, pulley arm, now.

Someone for the love of God, please provide guidance. Thank you to any and all!

 

Remove the alternator. Remove the oil fill tube (most likely to break it at the accordion end).
Remove the M5 allen bolt holding that little arm to the tensioner spring assembly from the back of the tensioner assembly.
Pry the right angle arm toward the back of the car until there is enough room for the wrench to fall out

On second thought, take the arm out altogether and have the 15mm bolt welded to the back of that right angle arm so you never have to use the wrench again.
Invent another name for the basterd engineer who designed that abomination.

 

2009 C2S 183K miles

Another way... take and Dremel and cut the wrench. I had the same thing happen to me on a different bolt. I was using a wratcheting wrench but it did not have a switch, you are supposed to flip the wrench. Well... can't flip it if you can't remove it. Out came the Dremel.

Peace
Bruce in Philly (now Atlanta)

 

I would first try to pull the bolt forward and out of the closed end of the wrench. Put a nut on it and screw it all the way to the bottom to pull the nut forward and out of the wrench. Then the wrench should be free enough to reverse the way you put it on at the start.

 

Cutting the wrench was my first thought too - I got one stuck like this taking a starter off my old F-150...angle grinded that POS off...then said **** it and angle grinded off the rusted bolt heads that I was fighting to remove in the first place

 

Issue resolved! I’m back in the saddle.

 

How did you get it out?

 

With brute force by prying the tensioner lever with another wrench.

 

don't tell us

 

Good go !! I would have suggested a pry bar ..... Just remember if it got on that way it will come off the same way ...No need to reinvent the wheel .... just a little patience.

 

Not entirely true. He put the wrench on while the arm was in a position with a lot of room in the back. Once he got the belt off, the arm pivots to a position where there is no room to remove the wrench, except by brute force. I really despise that design by the way. I don't see why there is the need for that bolt to be installed in the reverse position like that.

 

do you also like to build ships in a bottle