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Balance Shaft Rear Seals Replacement
 
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Pelican Technical Article:

Balance Shaft Rear Seals Replacement

Steve Vernon

Time:

9 hours9 hrs

Tab:

$3 to $110

Talent:

****

Tools:

Socket and wrench set, flywheel lock, flathead screwdriver, Loctite 574

Applicable Models:

Porsche 944 Turbo (1986-89)

Parts Required:

New seals, Loctite 574

Hot Tip:

Make sure engine is at Top Dead Center

Performance Gain:

Proper engine operation

Complementary Modification:

New belts

There are two balance shafts on the 944 engine, one on the upper left side and one on the lower right. Both of the shaft covers have a small circular end cap with a rubber O-ring inside to seal the covers. This small O-ring will dry out and leak over time; they all do. Unfortunately, replacing this small O-ring involves a lot of work for both shafts. We are going to show you how do it on the upper left shaft on a turbocharged car, because it is the most work of any off the versions of the 944. All of the procedures are the same for both sides. Depending in the options of your vehicle, it will determine what you need to move out of the way for the shaft on the lower right side of the motor.

To replace the rear O-ring or seal on the upper left shaft, you will need to remove the turbo and everything else associated with removing it, so this will be a really good time to do all the "while I'm in there " projects.

If you're going to do the lower balance shaft rear o-ring, you need to loosen the exhaust manifold for 1 and 4 cylinders and move back. Now take out the exhaust manifold for cylinders 2 and 3. You will need to remove the studs. Then pull the manifold up and out. Now support the engine with a jack so you can take out the motor mount bolts on that side. Once the bolts are out lower the motor just a bit. Now the balance shaft cover will come out.

You will need to remove the front mount and seals on the balance shaft (red arrow) to replace the rear seal.
Figure 1

You will need to remove the front mount and seals on the balance shaft (red arrow) to replace the rear seal. You will also need to replace the seals on the front, as they cannot be reused once the front is removed. Please see our article on front balance shaft seal replacement for additional assistance.

There are two brackets mounted to the A/C compressor mount, the engine lift point (red arrow) and a bracket that supports the heat shield and some vacuum lines (yellow arrow).
Figure 2

There are two brackets mounted to the A/C compressor mount, the engine lift point (red arrow) and a bracket that supports the heat shield and some vacuum lines (yellow arrow). Use a 17mm socket and loosen both bolts. The heat shield bracket will slip out by just loosening the bolt. Then you can turn the engine lift out of the way.

There are two sizes of bolts on the cover; the four on the front are 13mm (red arrows).
Figure 3

There are two sizes of bolts on the cover; the four on the front are 13mm (red arrows).

The remaining 10 bolts are all 10mm (yellow arrows), with two of them being shorter in length (red arrows).
Figure 4

The remaining 10 bolts are all 10mm (yellow arrows), with two of them being shorter in length (red arrows). Clean around the cover and remove the bolts.

You may need to gently tap the cover a few times with a rubber mallet to get the cover (red arrow) to separate from the block (yellow arrow).
Figure 5

You may need to gently tap the cover a few times with a rubber mallet to get the cover (red arrow) to separate from the block (yellow arrow). Do not jam screwdrivers or anything metal between the two surfaces!

Depending on the year of your vehicle you will find different means of supporting the balance shaft.
Figure 6

Depending on the year of your vehicle you will find different means of supporting the balance shaft. Our project car had a single bearing cap with an oil outlet for the line going to the turbocharger (red arrow). Make sure you note the orientation of the cap before removing, as the oil outlet will need to line up again upon reinstallation.

This photo illustrates the rubber O-ring or seal on the end of the balance shaft housing.
Figure 7

This photo illustrates the rubber O-ring or seal on the end of the balance shaft housing. You can see how the O-ring has shrunk and lost its ability to seal (yellow arrows).

Use a 10mm socket and remove the two nuts and washers from the bearing cap (red arrows).
Figure 8

Use a 10mm socket and remove the two nuts and washers from the bearing cap (red arrows). You will want to check the condition of the bearings in both the cap (yellow arrow) and the housing.

Remove the balance shaft and inspect it for damage (red arrow).
Figure 9

Remove the balance shaft and inspect it for damage (red arrow).

Remove the circular cap and replace the O-ring with a new one.
Figure 10

Remove the circular cap and replace the O-ring with a new one. This photo illustrates how the new O-ring seals the gap between the housing and cap (yellow arrows).

Clean both surfaces of the housing and cover and apply a bead of Loctite 574.
Figure 11

Clean both surfaces of the housing and cover and apply a bead of Loctite 574. The factory recommends applying the Loctite with a roller but just apply a small bead and smooth it out. If you have replaced the bearings make sure to use some bearing assembly lube on the new bearings. If you are using the old bearings using assembly lube is a good idea but at a minimum make sure the bearing is coated in oil before installing the shaft (yellow arrow).

Install the cover as well as the front mount (yellow arrow).
Figure 12

Install the cover as well as the front mount (yellow arrow). You do need to install all of the seals in the front mount yet but it does need to be in place for the torqueing of the cover. Install the bolts and torque in the pattern illustrated here. Installation of everything else is the reverse of removal.

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Comments and Suggestions:
Bill Comments: I am surprised this wasn't mentioned. If you're going to do the lower balance shaft rear o-ring, you need to loosen exhaust manifold for 1 and 4 cylinders and move back. Now take out exhaust manifold for cylinders 2 and 3. You will need to remove the studs. Then pull the manifold up and out. Now support the engine with a jack so you can take out the motor mount bolts on that side. Once the bolts are out lower the motor just a bit. Now the balance shaft cover will come out.
January 4, 2016
  Followup from the Pelican Staff: Thanks for the additional info and feedback. We appreciate it.
- Nick at Pelican Parts
 

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