wookie

The front of the engine is vibrating like crazy so I take a peek and what do I find? The "vibration damper/balance shaft gear" is lopsided?(see pic) So I take it off hoping that whatever is wrong will become blazingly apparent once I can see the parts, but to no avail. The best thing I can think is the front pulley doesn't seem to connect up to the vibration damper very well(see pic), I expected it to have some kind of ridge or something to ensure it was centered? But it looks like you have to do some wacky balacing act while re-wrenching the 191 ft/lb crank bolt? Or does this have something to do with tensioning the balance belt, etc.?

Any ideas?

http://www.5csys.com/rennlist/lopsided_gear.jpg
http://www.5csys.com/rennlist/cant_s...ter_these1.jpg
http://www.5csys.com/rennlist/cant_s...ter_these2.jpg
http://www.5csys.com/rennlist/front_pulley.jpg
http://www.5csys.com/rennlist/balanc...ion damper.jpg

wookie

thanks for the quick response!

i don't understand though?

I don't see any rubber where the balance gear sits with the front pulley? Did you mean in between the dampener and the gear? because that's not where is lopsided, it's where it sits (on the crank i guess) with the front pulley(then the 24mm bolt @ 191 ft/lbs)? It's got nothing in between the two to maintain centering?

ie the difference in these two pics:
http://www.5csys.com/rennlist/cant_...nter_these1.jpg
http://www.5csys.com/rennlist/cant_...nter_these2.jpg

and this is what i'm calling the front pulley(i don't see any part#s on it):
http://www.5csys.com/rennlist/front_pulley.jpg

wait, did you mean there should be some rubber in between dampener and front pulley?

thanks in advance,
wookie( 85.5 944 NA)

wookie

gez, left my brain in my other pants....try these:
http://www.5csys.com/rennlist/cant_center1.jpg
http://www.5csys.com/rennlist/cant_center2.jpg
http://www.5csys.com/rennlist/still-bolted.jpg

I'm not sure i get it, here is the bottom of the pic you linked to:
http://www.5csys.com/rennlist/whats_in_your_pic.jpg

and here's where it gets lopsided:
http://www.5csys.com/rennlist/lopsided.jpg

AlexE

The first pic is your crank pulley..... check to see that it is tight.

It may just be that the plastic covers are loose and it looks like the crank pulley is out of orientation...

AlexE

Oh ... and you may have the washer on the crank bolt backwards. This would keep the pulley from sitting flush and centered.

TheJonesBoy

I think I know what you did.

The crank has a ridge on it, which the pulley will self center on. If you tighten the crank bolt with the pulley not centered on the ridge, you pinch the pulley between the bolt and the crank, bending the metal of the pulley. Sort of like a punch making a new hole. Now it is seated lopsided.

Remove the pulley and look at it. Does the hole in the middle seem like an oval? If it does, get a round file and remove the metal you pinched, and it should fit on. Screw the crank bolt on by hand and check allignment before you torque it down!

MHT

the snout of the crank should extend thru the bal. shaft drive pulley, the hole in that pulley should have smooth sides and a keyway for the woodruff key in the crank. It looks as though yours was put on crooked, you can see a lot of metal shavings/dust in the area. I hope, for your sake, that the end of the crank is ok. You will need at least to replace the bal shaft pulley, make sure the cam belt drive pulley is installed with the flange facing outwards. The bal shaft pulley then goes on to the crank so that about 1/8" extends through the pulley, the power steering pulley sits on that and then you tighten the bolt. If the pulley looks like that you may also have damaged the woodruff key, check and make sure that it looks ok, has nice clean square edges, if it does not you will need a new one of those too. Good luck

wookie

thanks for all the great ideas guys!

i lowered a mirror in between the radiator and the crank and saw tiny metal shavings everywhere! i took these pics, its not pretty in there...

http://www.5csys.com/rennlist/mirror.jpg
http://www.5csys.com/rennlist/crank1.jpg
http://www.5csys.com/rennlist/crank2.jpg

between that having shaved metal everywhere and the back of the gear having the same thing, i'll have to clean the housing like crazy and replace both parts. i've got the 944 manuals, but i can't find anything about removing that off the crank, i'm guessing a gear puller is in order...

wookie

does anyone have any insight on getting this off the crank?

http://www.5csys.com/rennlist/crank3.jpg

wookie

why does the cover need to be off before you can tell me?

wookie

since when did asking a simple question merit a condescending answer?

of course i'll be removing the cover, i already said i was going to clean the housing/cover, how would i do that without removing it, besides how else would i retension any belts without doing that?

also as an fyi, if you had taken a closer look at the image i linked to with the mirror, you would see that the fans were already removed...

MHT

once you have removed the cam belt you will be able to grip the flange on the pulley with a large pair of channel lock pliers. I usually grab the flange and then tap the pliers with a hammer to remove the pulley. If things are really messed up you may have to use a puller.

Good luck Mark

wookie

awesome, thanks alot! i was trying to find out if i needed some special porsche gear puller or not, so if i did, i could go ahead and order one...you know how that goes, right around the time you get to something, you find out you need porsche special tool XYZ which is only available through mail order from austria, and then you got a week or two wait until it arrives before you can do anything!