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

[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.

[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 :-)

[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.