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

[healthservices]

Not that you did it wrong but if I remember correctly the timing tool for one head is not used for the other when the motor is at TDC for number one.

Am I correct?

[Jamesp]

Originally Posted by healthservices

Not that you did it wrong but if I remember correctly the timing tool for one head is not used for the other when the motor is at TDC for number one.

Am I correct?

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.

[seningen]

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.

Go get a boroscope and insert it into the spark plug hole
You'll need the more expensive, smaller one to fit into the spark plug hole.

You can see if there is valve strikes in the pistons

It will typically show up as a shiny half moon arc

If it's there, you probably have bent valves.

You really don't want to risk starting with bent valves

They could stick and break off
Which obviously would not be good.

Mike

[Jamesp]

The question I have is do you bend the valves 180 out of time? Surely this has been done before.

[BYprodriver]

Originally Posted by Jamesp

The question I have is do you bend the valves 180 out of time? Surely this has been done before.

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.

[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.

[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