:stupid:
I have broke one of the engine head cover studs clean off and inside the hole/thread. I need to get a torque wrench! I tried to drill the stud out of the camshaft cap but being aluminium I just made a mess. So therefore I have now taken the whole camshaft cap off and hepe to replace both this and the stud (both shown in the photo) to solve the problem. Im currently running the engine with out this but it is leaking a small amount of oil via the area where the stud should be.
I have the part number for my 2.4D Crankshaft Bearing Cap (#074 453 - #2 DE ) but also need the studs part number for reference. I have a VW T4 [1998] 1.9TD sitting on my drive and before taking its engine apart I was wondering if the parts would be the identical/swappable. Can you swap a single camshaft cap from another engine? Instead of buying a new one I could maybe use the 1.9TD one? Are the 2.4D & 1.9TD part numbers the same? Im hoping the cap doesnt only come complete with the head; as they are line bored perhaps? Can the single bit be changed at all? My biggest fear is that the only way to replace this would be to change the whole camshaft!
Here are the parts ive taken out/broken:
(http://img227.imageshack.us/img227/9412/dsc0060b.th.jpg) (http://img227.imageshack.us/i/dsc0060b.jpg/)
Im seriously gutted about this. What are my options of sticking a broken stud to the aluminium camshaft as a botch fix? Glue? Sikaflex? Special welding technique?
[size=18]ETKA[/size]
UPDATE 1: Ive found the ETKA link (http://etka.auto2.ru/)I was looking for but it seems like itd been offline :(
UPDATE 2: The English version is down but the Russian version is alive and well. "I dont speak Russian" you may then mutter? No problem as Google Translator can get you ETKA in English via this link (http://translate.google.com.ar/translate?u=http://etka.auto2.ru/epc/cat/vw/BO/2005/403/&sl=ru&tl=en&hl=&ie=UTF-8)!
~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
LWB 1996 2.4D called Cinders ---> http://cind3rs.blogspot.com
SWB 1998 1.9TD called Bumble ---> http://eru-bumble.blogspot.com
~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
First off, are you running it without the cam cap? I wouldnt do that, yes they are matched, so another may not work, it could seize the cam.
That broken stud should come out, warm the cap a little as the aly will expand more than the stud, should be no pressure so cant see why it wont come out easy.
Quote from: filbertFirst off, are you running it without the cam cap?
No I replaced the camshaft cap, but I am running without the stud holding the cover on.
Quote from: filbertyes they are matched, so another may not work, it could seize the cam
So what do you think my options are?
Quote from: filbertThat broken stud should come out, warm the cap a little as the aly will expand more than the stud, should be no pressure so cant see why it wont come out easy.
Too late ... Ive fooked the camshaft cap by drilling. It was broken well inside the hole and I couldnt see any other option.
Id try to fix the original cap first, if its not doable, then try another cap, but be sure it doesnt lock the cam, best to turn by hand first if you can before starting, then run for a bit and remove it and see.
is the pic, before you tried to drill?
Quote from: filbertis the pic, before you tried to drill?
Its after drilling, i.e. as it is now. The thread is completely all shot, the stud still in there and the hole bigger than the stud.
drill it out, tap it and use a larger stud.
or put in a timesert or preferably, a helicoil as opposed to tapping soft alu.
:stupid: helicoil is the way to go.
Ive been trying ... I cant get the bugger out :(