Help needed: Boxter fails to restart after rebuild / windows no longer work

[Jamesp]

Originally Posted by BYprodriver

NO, I'm thinking you just forgot to spin the engine 360 degrees after setting cam timing on 1-3 cyl bank, & prior to setting 4-6cyl bank. If that's what happened the valve to piston clearance is as designed but DME is not programmed to send spark & fuel at the appropriate time for 4-6cyl combustion stroke.

You called it! Thinking it over the valves cannot be bent as they are opening and closing at the appropriate time with respect to piston stroke, but the exhaust and intake valves have swapped places. Now its just a matter of more bolt twisting to get it right.

[Jamesp]

And I pumped out 15 gallons of gas yesterday.

[jsceash]

The quick check is pull the cam end seals out of both heads @ cylinder 1 and 6. Then Pin on the TDC hole. Check for the heavy side of the cam at the notch. On the one set both the thicker sides should be toward the head. On the other set both the heavy side should be away from the head. Both sets the slot should allign with each other. At 0 that also means they should be in line with seam between the head and the valve cover.

[Jamesp]

Originally Posted by jsceash

The quick check is pull the cam end seals out of both heads @ cylinder 1 and 6. Then Pin on the TDC hole. Check for the heavy side of the cam at the notch. On the one set both the thicker sides should be toward the head. On the other set both the heavy side should be away from the head. Both sets the slot should allign with each other. At 0 that also means they should be in line with seam between the head and the valve cover.

That's the next step. Good thing I do this for a hobby and not for a living or I'd starve.

[Jake Raby]

I have one set of cams out 180 degrees

I could have told ya that last night… I just wanted you to ID the issue and find it yourself.

The sound of the engine on the starter is all it took for me.

Don't feel bad.. This is the mistake that Porsche dealership technicians seem to make over and over again. They call me out of the blue needing help just like some guy out of the blue, but caller ID says they are at a dealership :-)

I usually won't bail them out with a 350 dollar consultation charge :-)

[Jamesp]

Originally Posted by healthservices

its sucks how we sometimes just miss one simple step and it totally fubars everything.

It's not technically FUBAR, If I had bent the valves, then Yeah, but as is it's not F****d Up Beyond All Repair.

[seningen]

Originally Posted by Jamesp

That's the next step. Good thing I do this for a hobby and not for a living or I'd starve.

My feelings exactly -- Glad I have a day job!

I can wrench if I have to -- but I prefer to drive than wrench -- but I get great pride in knowing that I'm racing what I wrenched on.

Mike

[Jake Raby]

My feelings exactly -- Glad I have a day job!

Hell, I don't even have a job. Its a lifestyle.

[healthservices]

Originally Posted by Jamesp

The timing procedure seems to go like this - Lock the engine at TDC and set the valve timing using the timing tool. Head 4-6 is shown first in the repair manual, but I dont see a difference in which head gets timed first as there is only one TDC sr=etting on the crank. Now for the part I missed - Roll the crank 360 degrees (that's half a rev of the cams) and see the other side. Now the cams are set 180 degrees out from one another. I have one set of cams out 180 degrees. BYprodriver hit it on the head.

I really wonder if the motor is a interference motor when the instructions tell you to just rotate the motor 360 with no regard to cam position?

[Jake Raby]

Originally Posted by healthservices

I really wonder if the motor is a interference motor when the instructions tell you to just rotate the motor 360 with no regard to cam position?

Trust that it is a heavy interference engine.
Not rotating the engine when setting cam timing only phases both banks of cylinders simultaneously.

This creates two 3 cylinder engines and the engine would run if it had batch fire injection and a wasted spark ignition system.

That sound on the starter tells the entire story when this occurs.

[seningen]

Originally Posted by healthservices

I really wonder if the motor is a interference motor when the instructions tell you to just rotate the motor 360 with no regard to cam position?

It doesn't take much -- a properly set engine whose IMS Sprocket slips and rotates slightly
will take out all the valves -- so this tells you that the clearance is very tight.
(it's one of Jake's 99 millions ways these engines fail :-)

Mike

[healthservices]

I just find it strange that the instructions would state to rotate the motor 360 with no regard to what the cams positions are???

Ah... maybe because when the cams is held in position with the cam timing tool none of the valves on that side of the head is fully open, thus no interference when the motor is rotated?

[Jake Raby]

Originally Posted by healthservices

I just find it strange that the instructions would state to rotate the motor 360 with no regard to what the cams positions are???

Ah... maybe because when the cams is held in position with the cam timing tool none of the valves on that side of the head is fully open, thus no interference when the motor is rotated?

The engine is designed to accommodate this due to the positions of the VVT arrangement.

Don't over think it. Set cam timing on bank 1, remove the tools, rotate the engine 360*, lock the crank, fit the cams and timing tools and fit the tensioner or pre-tensioner tool, then tighten it all up. Remove the tools and you are done..
No need in over thinking it or worrying about anything else.

Or just wait for my book to be published, which has 3 chapters on cam timing, to include 3 and 5 chain specific, step by step procedures.

[BYprodriver]

When the engine is at top dead center TDC, & the cams are properly allocated, all cam followers are on the base circle of the cams. All valves are seated.

This is why if the engine will not be started for a month or more you should put engine at TDC to unload valve springs.

[Gilles]

Originally Posted by Jake Raby

Or just wait for my book to be published, which has 3 chapters on cam timing, to include 3 and 5 chain specific, step by step procedures.

Jake,
How long would be for your book to be available?

.

[Jake Raby]

Originally Posted by Gilles

Jake,
How long would be for your book to be available?

.

Thats up to the publisher. The target is late spring.

[healthservices]

Originally Posted by BYprodriver

When the engine is at top dead center TDC, & the cams are properly allocated, all cam followers are on the base circle of the cams. All valves are seated.

This is why if the engine will not be started for a month or more you should put engine at TDC to unload valve springs.

I can understand that for number one... but what about cylinder 4 when 1 is at TDC?

lets say the Firing Order is 1-6-2-4-3-5 would it not stand to reason that the number 4 is at btdc and sucking in air with full lift? maybe I'm just reading too much into it.

[Walter White]

I think it's the gas, the gas is bad. Definitely the Gas. It's all bad.

[Jamesp]

Originally Posted by Walter White

I think it's the gas, the gas is bad. Definitely the Gas. It's all bad.

It's all good except the gas, and the valve timimg which soon will be. I'll mix the old gas with new and burn it in an old lawnmower. The smoke should kill mosquitos. What is good is that everyone on this string is learning (sadly from my mistake, I prefer to learn from others) or teaching. I'm about halfway getting the engine out to correctly time the valves. Then I'll spin it up again, and who knows?, it might start. Then it's on to the windows - and all the grounds were tight.

[healthservices]

Any updates?