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Author Topic: Crankshaft bolts  (Read 157 times)

Offline slow-n-steady

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  • Posts: 18
  • Thanked: 0
  • Model: Alhambra Mk1
  • Spec: 01 TDI 115 AUY+EHH
  • First Name: Steve
  • Region: South West
Crankshaft bolts
« on: November 20, 2020, 04:24:49 PM »
Crankshaft pulley socket head bolts rounded on AUY engine. 

Damaged bolt heads

Hi everyone,
Timing belt time again for my diesel Alhambra.  My first problem is that all 4 socket head cap screws (Allan screws) holding the aux belt pulley to the toothed belt sprocket have ‘rounded off’ internally. 
Despite what appears to everybody to be an excessive tightening specification (by the book, 10Nm + 90 degrees) there is no suggestion in the literature that they are single use fasteners.  My experience suggests they should be. 
When I last changed the belts etc. the 4 x set-screws were removed without mishap. 
They were re-used, but tightened to 10Nm + 45 degrees only. 
The bit used to tighten them was Cr-V and undamaged.  It still shows no sign of wear or other damage. 
The 4 socket head cap screws are stamped 12.9 so are the correct material at least. 
Now to the problem.  The caps are recessed within the ‘cup’ of the crankshaft pulley.  It is not possible to grip them around their outside. 
I appear to have a number of options, but not one of them is straightforward. 
1   First I have ruled out heat, by any means, because of the likelihood of damaging adjacent components. 
2   Have a toolmaker grind down 8mm hex Cr-V steel, to slightly over 6mm and hammer the new ‘hex bit’ into the hole, and try again.  The heads will not take a quarter inch Cr-V hex (being 6.35mm).  Maybe it could be hammered into position.  I haven’t tried yet, it is raining and my garage is the front drive! 
3   Drill them out, and once the pulley is off the sprocket, hope that the remaining shank can be drilled further without damaging the threads in the sprocket.  (I understand that 12.9 steel machines relatively easily.) 
4   Remove the sprocket from the crankshaft with the pulley still attached.  I suspect this is impossible without damaging the guard for the toothed belt.  Then have a machine shop machine them out.  This would probably work out more expensive than purchasing new sprocket, pulley and fasteners.  The cost for parts would be about £65 as far as I can establish. 
5   I don’t have welding equipment, but I suppose there is he possibility of welding the bit in place, and try again. 

Anybody have thoughts on any of these options please? 
Thanks, Slow-n-steady

Offline johnnyroper

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  • Posts: 2992
  • Thanked: 152
  • Model: Galaxy Mk2
  • Spec: 02 tdi 115 ghia
  • Region: South West
  • Country: United Kingdom
Re: Crankshaft bolts
« Reply #1 on: November 20, 2020, 10:16:07 PM »
I had same issue with mine,I hammered a 12 point socket on to remove them. From memory it was a 12mm 12 point half inch socket I used. You could also try hammering a torx or ribe bit in them. T45 size would do it. Hear what you are saying about heat but a bit of local heat with a blow lamp shouldn’t cause any problems. I wouldn’t use oxy/acetaline mind nor would I try and go cherry red.

Offline johnnyroper

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  • Posts: 2992
  • Thanked: 152
  • Model: Galaxy Mk2
  • Spec: 02 tdi 115 ghia
  • Region: South West
  • Country: United Kingdom
Re: Crankshaft bolts
« Reply #2 on: November 20, 2020, 10:18:43 PM »
As for drilling if that is how you end up going once heads are off and pulley removed the remaining bits will most likely come out fairly easy as the tension is off.

 

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