Down, but not out

[DOHCstunr]

ok well i got everything pulled today.

got the cover off and to my suprise the balance shaft belt is still intact.
so maybe my b/s belt bashing was premature.

i lined everything up at tdc, and oddly my oil pump sprocket was one full tooth off.

WTF

i know it was in time last time i took off the cover.
so i'm like well idk how it happened but i'll go ahead and fix it.

so i pin the tensioner, lossen the tensioner pulley,

go to reposition the oil pump sprocket/ rear balance shaft.....

it won't budge :shock:

turning it took all of my might and actually i could turn my axle by hand easier than my oil pump sproket.

i have another 4g63t block sitting in my office, that hasn't seen oil in over a year, and the oil pump sprocket turns with no effort.


my rear balance shaft is locked up.

so since i was going to delete it anyways,
i'm going to go ahead and drop the pan and check it out.

i suspect its a spun rear balance shaft bearing.

which would explain why the engine died so abruptly.
i'm just glad it didnt' tear up my timing belt or anything else skip time when it happened.

so my bad for knocking another balance shaft belt. i should have been knocking the rear balance shaft itself.

i wish they would have just fed it from the main galley's instead of through the shaft itself. oh well.


i'll take pics and get back to you guys.

back to the wrenching.

[SkylineG1]

Keep us informed and updated with pics

[Kalamidad]

good luck man...keep us updated. what are the temperatures like where you're at?

[DOHCstunr]

well it satarted out sunny and 55 degrees.
about two hours ago some clouds rolled in and it was still warm, but its started sleeting.

then it started getting cold and i'd say we are at about 40 degrees. with rain.

its dry under my car, but my legs aren't under it so....

getting kind of nasty out there, and the sun is starting to go down.
but i'm going to run an extention cord out there for a portable heater and some shop lights.



man i miss my garage.

[DOHCstunr]

Update.



ok so i got my front cover off.

pulled it out w/ the rear balance shaft.


but wait...

with the rear balance shaft off the bearing the pump gears should move freely.
and they don't.

oh crap.


what to do.

pull the oil pump gear casing off.

balance shaft gear spins fine,
oil pump gear siezed. :shock:

i tap the pump gear and shaft out with a mallet.
one bearing surface is shiny, the other side, dull and damaged. with little bits of material in there.

well, i think i found the problem. :?

so i guess i'll have to order a new oil pump case.
:evil:



oh wait,
i have another block sitting in my office.

i suppose i'll just take the oil pump case off that one and bolt it to to my current motor.

CRISIS averted!!

lucky day.

[seth98esT]

Crazy. Just use the casing off your Hyundai motor.

[DOHCstunr]

that hyndai block is in louisville.

luckily i have my old 4g63t block sittting here in richmond next to my PC.
i brought it down here to sell to a guy. and i never got around to closing the deal. now i'm glad i didn't. because i would have had to buy a whole new front case and oil pump, and then wait forever and a day for it to arrive.

time to chill out though this crap has been stressing me all day.

[SuperGALANT]

you are the luckiest and unluckiest man alive at the same time..

[DOHCstunr]

yeah its crazy when you have 2 and three of everything just lying around.

When things used to break the car would be down for weeks.
now i can break like 10 or 12 things while fixing just one thing, and they will not impede my progress.

But yeah i was lucky on this one. I'm just glad i never lost oil pressure, the timing belt wasn't damaged, and nothing other than the pump jumped time.

[seth98esT]

So the belt is fine? Get her running today, I know you want to boost your new turbo

[DOHCstunr]

<div class='quotetop'>QUOTE(seth98esT)</div><div class='quotemain'>So the belt is fine? Â*Get her running today, I know you want to boost your new turbo </div>

shhhh don't tell.

i'm just waiting for napa to get my front cover gasket set in so i can slap everything back on.
they are getting one from louisville and it will be here tomorrow. i ordered a new pan gasket to go with it.

one cool thing that came out of this other than the b/s delete. is that i had a bad exhaust leak where my downpipe meets my exhaust. so i'll get that fixed right up while i'm at it.

[DOHCstunr]

if you look closely there are 3 bearing surfaces. two on one side of the gear, one on the other.
its hard to tell in this picture, but the inner of the side with two surfaces is a dull silver color. whereas the other two are polished to a mirror.

well the dull silver surface should be polished as well, (most likely) foriegn materials that cause the pump shaft to sieze destroyed the bearing surface, as well as the journal of the front case. so niether could be reused.

lucky for me i had another front case lying around.

[SuperGALANT]

u should do a tutorial of what to buy to eliminate the balance shafts.. i know im gonna wanna do it if i end up takin mine apart for the headswap

[seth98esT]

superGALANT, you should check out www.vFaq.com for DSM tutorials. There is one for the BS elimination.

[peanotation]

wow, what a mess, how hard was it to take the shafts out with the motor still in the car? i'd imagine one would bump into the side of the engine bay

[seth98esT]

Rear balance shaft comes out no problem. Front is impossible to get out unless you: A) Cut the lip on the lower section of the body, or Pull the shaft out and cut it. I chose to do . Wasnt too bad, went through a few dremell bits though

[DOHCstunr]

the delete isn't really all that bad.

no one part is hard.

just little things like if your downpipe bolts are seized then you have to deal with that,
if your crank sprocket gives you trouble you have to deal with that too.
just a bunch of little things.

i think if i unbolted/ loosened the front crossmember bolts i could get the front shaft out. but its cheaper to just leave it in. i did go ahead and rotate the front balance shaft bearing to block off oil for extra pressure(the one closest to the drivers side. but i just left the one on the passenger side as it is cause its a pain to reach up in there and since i'm leaving the front shaft in, whats the point.


other than that its pretty straightforward.

[manybrews]

<div class='quotetop'>QUOTE(seth98esT)</div><div class='quotemain'>Rear balance shaft comes out no problem. Â*Front is impossible to get out unless you: A) Cut the lip on the lower section of the body, or Pull the shaft out and cut it. Â*I chose to do . Â*Wasnt too bad, went through a few dremell bits though </div>

Ive never had to do anything like that.
so Id say youre missing a step somewhere.

[seth98esT]

Hmmm I did not remove the crossmember so it probably could have come out with it removed but one of my bolts was already stripped for the crossmember so I did not bother.

[DOHCstunr]

Ok, well after battling the elements i have her all fixed up.

i replaced a couple of exhaust gaskets and my throttle body gaskets while the car was down.

started her up after priming the oil system, oil cooler, and turbo.

started right up. no leaks.

and oh man was she quiet. i must have had a leak at my downpipe to catback for a long time. cause its never sounded so healthy and quiet. just a nice sexy tone coming from the muffler.


I must say that my throttle does seem lighter. the engine seems like it wants to rev easier now. it is actually pretty cool.


as for the vibrations,
its only been a day, but the vibrations really are quite minimal. at least for me.
i was expecting low frequency, lumpy vibrations.

but they are actually pretty high frequency. high enough that you barely notice them at all.

Now, this may be premature, but i think i got more vibration out of my polyurethane motor mount upgrade than i did out of the balance shafts.

This is not to say that there is no noticible vibration, but its not the kind that will make your coke can rattle in the cup holder or your rear view mirror shake.



I'm just glad to have her running again. its been days.


i actually had to ride my bike 3 miles to napa to pick up my oil pump cover gasket set.
But its nice to be back on top again.

Setting the timing is getting to be something i can do in my sleep.

Thanks for the support guys.




i think the part that sucked the most was scraping the gasket material off the block and front cover. took me over an hour to get it all.