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T-belt and water pump r and r question

OK folks, I have a coolant leak by the water pump. I checked the hoses in that area, they were dry. I then removed the upper belt cover and everything was dry, but the belt on the right side moves about half an inch when pushed. (balance belt?). The belt on the left moves a little less. My records indicate that a re-manufactured pump and new belts were installed just less than 40,000 miles ago. I'm gonna get this car fixed. How hard is a timing belt/waterpump replacement compared to doing a clutch job on these cars? I judge everything on a clutch job, since that has been ths toughest thing I have ever done on a car. Any educated opionion very welcome!
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'87 944 Maraschino Red Metallic Euro delivery...five speed
Old 09-30-2003, 06:11 PM
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Novice owners do it all the time. Insurance is a flywheel lock to keep the engine from accidently turning.

It's recomended that you pull the balance shaft and crank pulleys to remove the back cover but I've cut the back cover in half just below the water pump and saved myself the trouble. Think I have a marked up picture some where that shows the cut.

Takes a day to do it the first time -- eight hours.
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Hugh - So Cal 83 944 Driver Person
NOT a 'real' Porsche -- Its Better!!!!
When was the last time you changed your timing and balance belts and/or cam chain and tensioner?
New Users please add your car's year and model to your signature line!
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Old 09-30-2003, 07:24 PM
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Thank you SoCal.
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Old 10-01-2003, 02:40 AM
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SoCal,

wish I would have thought to cut my rear cover; good tip
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Old 10-01-2003, 03:12 AM
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Quote:
Originally posted by repoman
SoCal,

wish I would have thought to cut my rear cover; good tip
Have to find that mark up. Two computers and 200 gigs of data!
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Hugh - So Cal 83 944 Driver Person
NOT a 'real' Porsche -- Its Better!!!!
When was the last time you changed your timing and balance belts and/or cam chain and tensioner?
New Users please add your car's year and model to your signature line!
Never break more than you fix!
Old 10-01-2003, 10:03 AM
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OK... I feel like I'm at a Jedi convention! SoCal... I know you must be VERY busy replying to imps like me, but I must ask for details. I wanna change ALL belts and water pump (plus all the rollers and bearings I need to). Can you recommend a site for details? I have the Haynes manual. I bet you know the whole mess well, I got a feeling! Hey, I wanna get this car in top shape and then sell her to get a 86-88 carerra.
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Old 10-01-2003, 06:27 PM
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Michael,

I used Haynes manual, Clark's garage web pages, Excellence 944 tech articles from back issues, and Blazak tool web pages. Overkill. Haynes & Clarks would be enough.

Car up on ramps, Special tools: Optclick tool, Lots of ziploc bags, paint pen for marking, flywheel lock, balance shaft sprocket wrench, gear puller, torque wrench. feeler gauge, digital camera

did belts, turbo water pump, belt tension rollers, front balance seals.
turbo pump is a noticable improvement.

toughest parts were pulling crank pulley and removing/attaching dist cap.

taking my time, methodical and doublechecking took 8 hrs divided up into 2 hour segments. not hard to do at all. have fun
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Old 10-02-2003, 05:33 AM
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Thanks repoman. Your reply makes me feel better. Balance shaft wrench... thats a new one. I can borrow all the other ones but that and the tensioner tool.
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Old 10-02-2003, 06:04 AM
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Make sure you install the belt idler pulleys in the correct orietation. One side has a lip. Do not reverse them.
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Old 10-02-2003, 06:17 AM
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You can get by without the special balance shaft wrench. Go to a local tool house and ask for an adjustable spanner (not the Brit version). I got mine for $12. They are used to change the wheels on surface grinders.
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Old 10-02-2003, 06:19 AM
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Pelican probably sells these too:

Performance Parts p/n

904996 balance shaft sprocket holder; used to hold sprocket in place when tightening hold-down nut

911741 tension adjuster; for turning balance belt adjuster

couple things I remembered:

before checking tension on timing belt, hand rotate engine 1 rev; this evenly pre-tensions belt.

no requirement to do this to balance belt

On timing belt tensioner mounting stud: it's recommended to replace but I couldn't see a way to remove mine without damage so it stayed.

It is very important to apply counterforce to this stud when tightening, loosening tension roller. Otherwise you will weaken it and if it breaks with engine running....

I'm no 944 expert but decent mechanic. I repeat, with documentation and proper tools this is an easy job and well worth the piece of mind.
great thing about 944 is all the DIY info on web. Other reference I used was 944 maintenance video & all the postings on belts & waterpumps in this forum

My car was re-engined 45K miles ago from previous owner. My old timing belt was spot-on concerning tension but had a very small fray on edge. Balance belt looked like new. Car had been parked dead for 5 years.
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Old 10-02-2003, 06:31 AM
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Dave951,

now do I feel dumb! I already had one of those spanners!

oh well, not first time I bought an extra tool

on related note I found a 24" long 1/2" drive in a 3' cheater bar worked well for hand-rotating engine.
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Old 10-02-2003, 06:38 AM
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You only need the pin spanner and large breaker bar if you don't cut the back cover in half.

You do need them if you have to reseal the balance shafts and crank front main seal.
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Hugh - So Cal 83 944 Driver Person
NOT a 'real' Porsche -- Its Better!!!!
When was the last time you changed your timing and balance belts and/or cam chain and tensioner?
New Users please add your car's year and model to your signature line!
Never break more than you fix!
Old 10-02-2003, 07:23 AM
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OK. I've found my mark up on cutting the back cover. Remember I have an 83 so the back cover was never modified for the newer water pump and the metal "fence".

Here:

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Hugh - So Cal 83 944 Driver Person
NOT a 'real' Porsche -- Its Better!!!!
When was the last time you changed your timing and balance belts and/or cam chain and tensioner?
New Users please add your car's year and model to your signature line!
Never break more than you fix!
Old 10-02-2003, 03:05 PM
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would it be possible if we got a sticky on the board that lists all the parts and tools needed to do a complete belt job? when i say complete i mean seals pump and everything?
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Asking if you should replace that timing belt is like asking if you should re-use a condom that may have in hole in it with a hooker.
Old 10-02-2003, 03:25 PM
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Sticky should say, "do a search of this forum" ;-)

Search - belts and tcmdocs944 - I posted lots and lots of pics of the whole process and got some great answers to my questions. Also search - belts and overkill - good info and at worst you'll get a hell of a laugh finding out why his name is overkill.
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Old 10-02-2003, 03:47 PM
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Oh, Socal...great pic!
Can't decide about cutting though...moot point as the next time I am in there I will be fixing the slow leak at the crank.
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Old 10-02-2003, 03:48 PM
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If you are resealing then do all of the shafts. Have to take the cover off then.
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Hugh - So Cal 83 944 Driver Person
NOT a 'real' Porsche -- Its Better!!!!
When was the last time you changed your timing and balance belts and/or cam chain and tensioner?
New Users please add your car's year and model to your signature line!
Never break more than you fix!
Old 10-02-2003, 03:55 PM
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