2.5tdi BDH Timing belt tensioer woe

[billybob]

Got there in the end. Onwards and upwards!

[billybob]

The source of the problem is now exposed - sheared off bolt on the tensioner pulley, sigh!

Is there anything to try which may have remote chances of success? Having recently seen a thread about what's involved with regards to removing and replacing the housing I don't think that's an option for me, if I could even find one.
Are there any options for getting the rest of the bolt out (sheared 0-1mm below the face of the housing)?

[Crasher]

Can you post a picture?

[billybob]

POORLY BOLT.jpg

Got a long list of jobs needed for this car even if it was recoverable but not much to lose before I put bits back on and arrange for it to be taken away I guess so I've tried drilling a hole in the 'middle'. I'll try enlarging this a bit then I have a set of bolt extractors that I've had for many years yet never used that I can try and see if one bites. This will be my first attempt at such a procedure and I'm not feeling too optimistic tbh unless the bolt is not tight but I think it will be, or crossthreaded etc. From what I understand if you don't do the cambelt change according to proper procedure (lock everything, cam sprocket off etc.then putting that back on as the last item) then often the tensioner pulley thread gets messed up due to someone trying to put that on as the last item instead. As my sprockets etc. had paint marks on them I'm thinking that cam sprockets weren't loosened / removed and the job was possibly bodged on first cambelt change (service history just had a receipt for a belt, nothing from a garage etc.).

Anyway, back on topic! For some reason my set of bolt extractors came without a tap wrench type bar (likely a cheap set) so no good way of turning the extractors presently. I have to try and get hold of one of those now though don't feel I'd be able to get a lot of weight behind one whilst trying to turn it. I've seen a different set that you can put in a driver which I would have though you could get a lot more weight behind whilst running at a low speed to possibly give a better chance of not slipping in the hole (in my mind at least) so maybe I should get hold of a set of those instead. I imagine I don't get many shots at trying to get the extractor to grip

[Crasher]

Even if you get the stub out, the mounting surface is damaged and a new roller won’t sit square so new front plate but early and late ones are both obsolete.

[billybob]

Thanks Crasher. Good to know about the (lack of) availability of that front plate though having read of someone else's struggles replacing it I would likely have not undertaken the task. As it was I couldn't get the stub out anyway. Managed to drill a small pilot hole but struggled to enlarge it (poor quality drill bits possibly). Had a half hearted attempt with a couple of bolt extractors tools but I had already decided I was going to look for a replacement car whether I managed to get it out or not. I've put the front end back together now as it was. If anyone has an interest in the car as a donor for others or as a project and and is willing to pay the equivalent of scrap value drop me a line. It's an A4 Avant 2.5tdi quattro, 2004 with BDH engine and 6 speed manual box with 2 new Toyo Proxes Sport tyres if nothing else . I didn't bother looking under the valve covers as wanted to see what had gone wrong first. Whilst the belt had gone a bit slack due to the sheared tensioner bolt it hadn't actually jumped any teeth etc. and engine seemed to run normally until you came off the gas then it would die (I guess due to the timing going off a little once the belt was under less tension from the crankshaft under acceleration)