Broken Drill Whilst Changing Cambelt On Galaxy

[galaxy1609]

Hi,

 

I was wondering if anyone can help me on this one!

 

I decided to change the cambelt on a 2005 galaxy 1.9 tdi 115 and everything was going well and I was taking my time and following instructions to the letter.....however......once I had finally got everything done and was about to give then crankshaft tow turns to make sure that everything lined up things started to go wrong.

 

I removed the crankshaft locking took but once it came to removing the camshaft locking pin it would not budge.

 

After some time and with lots of twisting with a pair of vice grips it did eventually come free, at this point I would like to to add that I did not hammer the pin into place! I did take a few wiggles to fully lock but no great force was needed.

 

Now thinking that the locking tool might be at fault I decided not to use it and opted instead for a 6mm drill bit which went in very easily and much easier than the original pin went in.

 

However after refitting the belt and making sure everything was aligned to give two turns of the crankshaft upon attempting to remove the drill bit this too had become jammed. Unfortunately it was very jammed and eventually the drill broke inside leaving about 1cm of drill bit in the hole.

 

My question is can I simply drill out the old drill bit and was is causing the locking pin and the drill bit to become jammed in the first place?

 

Hope someone can help, Thank you.

[insanitybeard]

Is the broken drill bit now stopping the camshaft from rotating? I would say that the locking pin must pass through the camshaft sprocket and hub before engaging in a locating hole in the cylinder head. The camshaft sprocket is easy enough to remove by unscrewing the 3 x 13mm bolts surrounding the larger (18mm?) centre bolt- NOT the centre bolt itself. With the sprocket removed, can you then get a grip on the remaining stub of drill bit? If not you may need to remove the camshaft hub which looking at this parts diagram is a tapered fit on the camshaft and should be removable once the large bolt in the centre of the camshaft is removed, though it looks like the hub is keyed and tapered to the shaft so it'll likely be a tight fit. With the hub removed hopefully you will then be able to pull the remaining stub of drill bit out. I wouldn't bother trying to drill out a broken drill bit, especially in situ, the metal it's made of will be too hard and you will never be able to accurately drill it without enlarging the surrounding hole or damaging something else.

Edited June 19, 2014 by insanitybeard