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Hi Guys, I am doing my timing belt and water pump on audi 80 2.6 1994 and have hit a wall. The garage that did the last change did not replace the 8 crankshaft pulley bolts or the tensioner bolt and they are all half stripped by them to start with. The tensioner bolt is completely stripped(not by me) and I'm sure will be a further problem when I get to it. I have managed with some difficulty to get six of the eight pulley bolts out. Four came out just being super careful and tapping in the allen tool all the way, two came out with a screw extractor but the final two are refusing that method also. I removed the fans and radiator for access but now think I will have to take off the bumper next to try to get a decent angle on them to drill. Any thoughts or techniques for these wee suckers? Thanks
This pic shows that the garage also just did the tippex and pray method of changing the belt. The tool does not line up both camshaft with the crankshaft at TDC. The new white marks are mine put there out of curiosity to see what happens after Ive sorted things but there are old white marks on the sprockets already and so I suspect that the garage didn't pull the camshaft sprockets or use the tool. I guess they just slipped the old belt off and put a new one on and tensioned. The belt is the proper tightness around the tensioner and also very tight between the two camshafts but it is so loose between the left hand (US driver side) camshaft and the crankshaft that I can actually lift it up and it interferes with itself as it leaves the waterpump pully. A very poor show really from a supposed audi specialist garage. Anyway, if I can get these darned pulley bolts out I'm hoping for a bit better fuel economy after putting the timing right.
I've head to deal with those bolts not coming out, but audi also has tendencies of using "soft" hardware, replace them with higher grade bolts, you can obtain those online, just measure the specs of yours first. and it looks like you are no the right track, but are you certain your crank is in the correct lock position? you are using the crank lock tool?
btw, is that lada 2106 in your avatar?
Thanks for the reply. I saw the Lada pic on the internet and just love the dog hatch idea! I already got the new crankshaft pulley bolts from an Audi dealer when I bought the new timing belt and pulleys kit but maybe after all this hassle I should go for some harder bolts. I also bought new camshaft pulley bolts from them just to make sure the torque settings on them is correct. I'm now looking at mail ordering some torx screw extractors that might have a better cutting face on them than what I've currently got. They are used with a drill and have a much smaller thread like a tap set. They might just get a grip before carefully hand tightening them. Downside is it'll be Tuesday or Wednesday at the earliest before they get here and this is my daily car. Upside is a bit more exercise!
Yes, crank locking tool is engaged. The crankshaft is firmly locked in TDC. I'm pretty certain the timing was botched by the last garage because they didn't bother using the tools. Think it's quite common after reading a lot on here about folks that don't want to spend the money on the correct tools. I'm guessing there are lots of garages that also don't want to spend that money and don't loosen the sprockets for the belt tightening. I didn't know and it has done 70,000 miles like this which is really quite amazing.
Before I started, I had a good listen to the engine so I could compare the belt sounds afterwards to see if I get the tension correct. I noticed that the two banks sound slightly different. One makes a slightly tappety noise which I take to be the hydraulic lifters being a bit loose (maybe oil pressure)and the other side a drier clickety noise. Now I'm wondering if it was all actually to do with the timing being wrong probably on both sides.
lol
as for extractors, i used something like this one http://www.autotools.com.au/images/products//8950.jpg
and just grind it down the tip till it fits and used a hammer to drive them in further, same trick might work with the ones you are using.
as for the bolts, replacing cam bolts is a good idea, and for the other ones, i usually go to ACE hardware or order them online. but audi bolts are something like 8.8 grade and i got tiered of striping those dang things, so i usually try to go 9.8 or greiter.
Thanks for the advice. Much appreciated. Your extractors look kind of square with sharp cutting faces. Think I can mail order some of those type made by Teng tools from amazon if I get no joy with mine tomorrow. Good idea to grind them down to fit better and will do that tomorrow. Don't really want to take the bumper off as it will probably break some discontinued plastic clips or something but I might have to if I end up drilling out the heads.
that's exactly what they are yeah, removing the front bumper is a pita, but sometimes you just have to. also you might be able to grab the heads of the bolts with vice grips http://st.depositphotos.com/1005187/...-vice-grip.jpg
I just had to remove some rusty stripped out pulley bolts. I need to look at the exact tool I used..(I'm out of town) but it was a twelve point metric star wrench..I think 6mm.
Tap the star wrench with a small hammer into your stripped out allen heads and they come out easily..
04-09-2016, 01:39 PM
crankshaft pulley bolts stuck ideas?
I already got the new crankshaft pulley bolts from an Audi dealer when I bought the new timing belt and pulleys kit but maybe after all this hassle I should go for some harder bolts. I also bought new camshaft pulley bolts from them just to make sure the torque settings on them is correct. I'm now looking at mail ordering some torx screw extractors that might have a better cutting face on them than what I've currently got. They are used with a drill and have a much smaller thread like a tap set. They might just get a grip before carefully hand tightening them. Downside is it'll be Tuesday or Wednesday at the earliest before they get here and this is my daily car. Upside is a bit more exercise! 
