[JCS2]

Has anyone removed the balancer shaft sprocket in a 2004, 2.4L K24A engine? If so, was there a woodruff key of any kind to keep the sprocket in place? I just removed mine and there is a gap in the sprocket and in the shaft that could house one, but I didn't find it. I have not seen one in any online schematics. The Haynes manual refers to a dowel pin where I would expect the woodruff key to be, but I've never heard it called a dowel pin. I'm trying to set the balance shaft timing and need to align the "dowel pin" on the shaft and mark on the pump housing, but can't tell what the dowel pin is and I can't tell what keeps the sprocket locked into place on the shaft. I've scoured the internet and this site with no luck.

 

[Tigris99]

Did you simply happen to have the key fall off without realizing it?

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[JCS2]

I don't think so. In retrospect I think it broke into bits. When I removed the sprocket were bits of metal came off with it. At the time I thought it was residual metal from valve/piston damage from the timing chain failure. Connecting bits of information together I now think the key is part of the balancer shaft (hence that's why there is no part number for it) and not a woodruff key. If anyone out there can confirm this, it would be great.

 

[stlmo]

Do you have a keyway milled in both the shaft and sprocket? If so, then most likely there was a key there at, and if you had things lock up with the timing chain failure, that probably caused the sprocket to spin and shear the key. We do a lot of machining of these types of parts, and very rarely would you have the key machined onto either of the parts. You can measure the width and depth of the keyways and find a key at the auto parts. If one of the keyways has a radius milled in the bottom, they it would be a woodruff key.

 

[Tigris99]

It wouldn't be part of the shaft, would be part of the sprocket like the crank sprocket is.

Just go to the auto part store with the sprocket and get the one that fits the groove.

Chances are though if that broke then the balance shaft assembly is garbage because it got metal in it.

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[JCS2]

Do you have a keyway milled in both the shaft and sprocket? If so, then most likely there was a key there at, and if you had things lock up with the timing chain failure, that probably caused the sprocket to spin and shear the key. We do a lot of machining of these types of parts, and very rarely would you have the key machined onto either of the parts. You can measure the width and depth of the keyways and find a key at the auto parts. If one of the keyways has a radius milled in the bottom, they it would be a woodruff key.

Yes, there is a gap in the balancing shaft too. I am off to the auto store tomorrow to find a key. Thank you!

 

[JCS2]

It wouldn't be part of the shaft, would be part of the sprocket like the crank sprocket is.

Just go to the auto part store with the sprocket and get the one that fits the groove.

Chances are though if that broke then the balance shaft assembly is garbage because it got metal in it.

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There were metal pieces in the balancing shaft area when I took it apart and cleaned it the first time (removing the sprocket was the second time I took it all apart). The oil pump is work though as I have good pressure. The shafts appear to spin freely so how would I know if the whole assembly is garbage?

 

[Tigris99]

Take it part and check for damage to the balancers or any other moving parts. Make sure there is not serious damage as it can cause vibration issues or even worse, lock up or break.

Also replace the oil pump internals if there is any grooves or anything in there. Better safe than sorry and the couple parts for the pump to rebuild it are fairly cheap and good insurance.

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[JCS2]

I just bought a used pump/balancer assembly from ebay. If the picture is accurate, it should be a good replacement. This should eliminate uncertainty about a woodruff key or internal damage. I will update when I have more. Thanks for all the help.

 

[JCS2]

Update on old oil pump shaft.

I removed the old balancer/oil pump assemble and removed the sprocket. I didn't realize it before but the direction of the gap where the sprocket goes over wouldn't work as a woodruff key holder to marry up with the sprocket. I am really stumped with this. When the used assemble arrives I will know for sure how the sprocket is supposed to go on and what the "dowel pin" the Haynes manual describes really is.

. I think I uploaded two images but I can't see them in this post. If you can't see them let me know, and I'll try again.

 

[Tigris99]

Well that thing is definitely chewed up, there's your problem.

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[JCS2]

Balance Shaft Chain Tensioner

Does anyone know why one is to use a new Balance Shaft Chain Tensioner when installing the oil pump/balancer chain? From the looks of it there is no spring or anything they needs re-aligning. When I put the old one back in place it applies tension to the chain to prevent it from slipping. It seems like it would work just fine. What am I missing?

 

[JCS2]

Its a dowel pin!

Well one mystery is solved.....the balancer shaft has a small pin built into the end of the shaft for the sprocket to slide over. It looks too small to provide and mechanical force so it must just be an alignment pin. Here is the end of the balancer shaft of my new assembly.

Now I just need to install it correctly timed with the crack sprocket. Stand by........

 

[Tigris99]

It's the plastic guide in the tensioner and that it's a spring without any retainer You always replace parts like that when rebuilding and engine.

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[JCS2]

Just to close the loop, I installed the used balancer shaft assembly properly and the engine runs smooth now.