Broke retaining bolt on cambelt idler pulley on 90 200,

[Fred Munro]

Hi Mike;

I've never personally had this happen, but it is apparently a relatively
common experience if you are not careful with assembly and torque. If you
try to pull the idler pulley in place with the bolt, you will snap it off.
You have to seat the pulley assembly before you tighten the bolt.
Unless you've stripped the threads in the block, you shouldn't need a
helicoil. Remove the pulley assembly and see if enough of the bolt shaft is
sticking out of the block to grab with vise-grips or a stud remover. It
should come out fairly easily. If not, centre punch the bolt and carefully
drill it for an easy-out. If you use a left hand drill bit, it should come
out on it's own during drilling.
Get a new bolt, drive the pulley home in the socket before you install the
bolt, and torque it to the proper Nm spec. Note that the Bentley has the odd
Nm to ft-lb conversion error (the ft-lb numbers are wrong), but the metric
numbers seem to be OK.

HTH

Fred Munro
'94 S4

-----Original Message-----
From: quattro-bounces at audifans.com
[mailto:quattro-bounces at audifans.com]On Behalf Of mike posner
Sent: December 6, 2003 8:31 PM
To: quattro at audifans.com
Subject: Broke retaining bolt on cambelt idler pulley on 90 200,


This is i very skinny bolt that I easily twisted  off while attempting to
tighten . Looks as if  It will need to be drilled out
 and  and a helicoil installed.  Anybody  BTDT with this?

Thanks,  Mike  ,
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