Avanthead

Recently took the 95.5 s-6 to have a "Routine" timing belt service. No big deal right? WRONG! The bolt had seized inside the crank and no amount of force (1,000ft/lbs) was going to free it. Long story short, the key way sheared off during this exercise un-noticed and moved the piston up which did god knows what to the head. Mechanic, a long time Audi Mechanic and respected was dumbfounded by the whole ordeal. He began a search to just replace the engine and found others had similar problems and were actually duped into purchasing engines with similar fates.
Has anyone had a similar situation that could shine light as to my next step?
We need the car back on the road ASAP.

scarman

Are you using a 3256 crank locking tool when trying to remove the bolt? With the keyway done for, using an impact gun won't cause any problems now. Hmmm, 1000 lb-ft you say, or he say??? What would you think it would take to shear that bolt off?? Do I sound skeptical? Of course, I am not there, but I have never seen a bolt resist a 3/4 breaker bar and 6' extention with 200+ pounds on the end.

The next step should be to not rotate the engine any more until you can determine how far the timing belt pulley moved and if any valves were hit. You might get lucky. Otherwise, might as well take the head off now.

Avanthead

Per our phone conversation he extended the breaker bar by 6-8 ft with a piece of steel pipe. I'm in agreement that we up the ante until the bolt moves, break another bar or shear the head off. The 1,000 ft/lbs is based ON HIS JUDGEMENT/experience and the fact he is a very hefty individual.

Open to anyone with ideas or similar experience.