1989_90_Quattro2.3

While doing a timing belt replacement on my 1989 90 Quattro, I was installing the new tension idler. After tapping in the idlerI was tightening the small bolt(7 ft/lbs) in he center holding on the idler and it broke before even becoming snug. I tried drilling and EZ-outing the bolt with no success. Any suggestions?

Loudgoldwing

If it broke before being snug, I don't understand how it's stuck now. Regardless, the best thing you can do right now is:

1) Soak the bolt with PBlaster penetrating oil.

2) Let it sit for 10 minutes.

3) Buy a few "eyeglasses screwdrivers." Make sure they're the flat-bladed type, about 2mm wide.

4) Sharpen the blades of the screwdrivers by rubbing them against some sandpaper on the garage floor.

5) Gently at first, then gradually more aggressively, hammer-tap the first screwdriver into the "meat" of the bolt.

6) After each set of 5 hammer strokes, pull the screwdriver out and check to make sure it's still sharp. You DON'T want to break it off in there.

7) When you put the screwdriver back in, MAKE SURE IT'S in the same position! Best idea? Make a "-" sign, and just keep putting the screwdriver back in that position.

8) After about a total of 50-75 hammer-taps, soak the bolt with the oil again.

9) Tap a FRESH (and UN-sharpened) screwdriver GENTLY once or twice to seat it in the notch that you (hopefully) cut in the bolt, and try to turn it out.

10) Drink heavily, be it for the purpose of celebration, or mourning.