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Discussion Starter #1
Because I screwed up (and as such am asking for help :oops: ) I thought I'd treat you all to the tale I'm calling "The little 5 mm allen head bolt on the cam positioning sensor that could"

Once upon a time there was a 23 year old Alfa Romeo 164L, which, as a result of poor financial sense, had come into the possession of a man with more cars than common sense. The man liked to say he was a 'shade tree mechanic' :nono: and this was good, for the little Alfa needed an overhaul. The man, following the how-to guide provided helpfully by the folks on the Alfa BB system, had so far with minimal cursing, :censored: managed to get to the step that calls for removal of two very special bolts on the road to timing belt wonder; one of which, was the little 5 mm allen head bolt on the cam positioning sensor...that could.

Because he hoped to complete the task and actually enjoy his financial recklessness, the man quickly assembled his 1/4 inch drive socket and allen key set...and immediately rounded the heads of both this bolt, and his brother. :crying:

"aha!" thought the man, after a bout of :cursing: "but there are ways of dealing with bolts that are frozen such as these! No bolt has ever held me up before!" But the little 5 mm allen head bolt on the cam positioning sensor told itself "I think I can, I think I can, I think I can." Even as the man got out his 6mm allen key set, even then, the little 5 mm allen head bolt on the cam positioning sensor told itself "I think I can, I think I can, I think I can!" With a Colossal WHAM! Now not only was he rounded, but both he and his brother were damaged beyond normal function due to the attempt at using a 6mm allen key attachment. Clearly the man however, was not discouraged.

After a spirited dance in rage :taz: the man thought :sailor: "Aha! But there are ways of dealing with bolts that are frozen and deformed such as these! No bolt has ever held me up before!" Yet as he got out his Torx set and set to work on his brother, the little 5 mm allen head bolt on the cam positioning sensor told itself "I think I can, I think I can, I think I can."

It was then with a mighty CRACK that the little 5 mm allen head bolt on the cam positioning sensor saw that his brother had been wretched loose at last, removed from his home, and set aside by a now elated shade tree mechanic :clap:

"Aha!" said the man "But I am almost ready to move on and get to the goodness that is removal of the timing belt cover, and from there, none shall stop me!" All this while though, the little 5 mm allen head bolt on the cam positioning sensor thought "I think I can I think I can I think I can!"

Now ready to continue the man suddenly forced the T40 torx upon the helpless bolt, and with a great thwack! :tank: drove the T40 Torx bit into the deformed head and readied his 1/4inch drive. "Aha! but now you shall be removed and bested, just like your brother, and in no time I shall be setting the engine to TDC and enjoying progress for no bolt has ever held me up!" said the man in joy.

"I think I can, I think I can I think I can!" went the little 5 mm allen head bolt on the cam positioning sensor. And with a mighty grunt, the Man tried... and only succeeded in rounding the head again. Even when he brought forth a mighty dremel tool powered by the A/C inverter in his Vanagon, with a cry of "Aha! but with a dremel powered by my idling VW Vanagon, I can surly cut a groove into this fatal bolt and then use a flat headed screw driver to remove the culprit! No bolt has ever held me back before!" the Man exclaimed to the worried looking neighborhood children watching from across the way.

Yet even then the man could not best the little 5 mm allen head bolt on the cam positioning sensor which after two days STILL told itself "I think I can, I think I can, I think I can." Frustrated at last, the man, with his last bit of sanity :wacko:, wretched once more with a pair of vice grips upon the hapless bolt, and twisted!
"I think I can, I think I can, I think I can!" cried the little 5 mm allen head bolt on the cam positioning sensor. And with a colossal THUD! the sheet metal of the bracket to which our mighty hero so clung sheered off taking the cam positioning sensor with it...

And the Little 5 mm allen head bolt on the cam positioning sensor that in response to the man's boasts of never letting a bolt halt him chanted "I think I can, I think I can, I think I can".... Could.

:dots:



So, uh, yeah, my cam positioning sensor bracket sheered. Don't suppose since it's not a major load critical piece of metal I can epoxy it back together or something? Because I met my match, and it was a 23 year old piece of aluminum that was poorly maintained. er... Help!?
 

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My situation with those a couple weeks ago didn't escalate like yours, but I did immediately go out to buy a 3/8 drive 5mm bit for that. I'm pretty sure I started to twist a 1/4" drive, long 5mm bit. Not sure why somebody goes magilla gorilla on those little guys.

I don't know if I would epoxy that. If it lets go you've got a bit of metal that may be bouncing around near the crank pulley, with potential to find its way between the belt and pulley. Who knows. I believe it'll all be somewhat contained in the lower covers. Post a pic of the broken part.
 

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Discussion Starter #4
The truth is I didn't plan on going all out. Years with Porsches (and the germans love allen head) taught me caution. Sometimes I screw up anyways. On the plus side I don't think the epoxy sight would be stressed as the other fastner and means of positioning would keep things on the level. I'll try and post a pic below
 

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So you need a good used cast aluminum crank position sensor bracket? I have a good used one (with a less recalcitrant allen bolt). I assume you are in the USA? $10 plus shipping? Let me know if you want it.
Charles
 

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Just to clarify, I wasn't calling you a gorilla! In my case, the guy who over tightened them.

I would take Charles's offer unless it needs to get done ASAP.
 

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Discussion Starter #7
no worries, I thought about it and realized what you meant. I think I shall too, I just, er, need to figure out how to get rid of the bolt as it's still in there :-D
 

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Discussion Starter #8
my original thought on it all was; repair the bracket, get a new top bolt, secure it in that fashion before the temperature drops (this week) then schedule a day to drop it off at the local specialist and let them work in their heated, well lit garage, full of all sorts of power tools, to replace it with the new bracket.
 

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Great story but picture a bit dark so my question to you is what bolt that could is still in place torqued tight? Is it one of the two that holds the bracket to the front engione cover or the one bolt that holds RPM/Timing Sensor in the bracket?
 

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Discussion Starter #10
One of two that holds the bracket to the front cover.
 
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