Kitty relaxing on my shoulder after my grandson ( who wanted to pull his ears ) was given back to his mom.

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:)

I know this is an engine rebuilding forum - just wanted to show some traffic Porsches will encounter in Africa. From my trip in April.

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Rockers installed on # 1 and # 4. This is where the fun starts -

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Sprocket alignment
 

I got fluctuating readings when measuring the cam sprockets , but adding an angle to the straight edge to make it more rigid , solved the problem.

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Small parts like washers and woodruff keys tries its best to defeat gravity and will even attempt to fall upwards in their quest to look for a way of getting into the case.

Cam timing
 

With cam sprockets aligned , I set valve clearance in # 1 using the Porsche tool. Dial indicator set up in Z- block .

When turning crankshaft 45 degrees of TDC I feel resistance. Did not want to force , and decided to ask advice first.

With rocker on # 1 and dial indicator removed same problem.

Which cylinder would be causing this ( # 6 ? ) , and what is the next step ?

Cylinder deck height problem ? - like Mark told me weeks ago.

Without any rocker arms installed, do you still get a residence while slowly turning the engine in a clockwise rotation?

Mark - yes , I was very careful , and tried it a few times without using force. I even very slowly turned the crankshaft back about 180 degrees without any problems. I did not want to hang the chains , and kept tension on them.

The resistance is clockwise 45 degrees from TDC.

The crankshaft turns 2 times for every time the cam turns , and cylinder # 6 is next in the firing order -

Well I guess we need to know just how much resistance it really is. Can you rotate the engine past the hard spots and get a full 360 degrees? What I'm trying to figure out is are the hard (resistance) spots just slow you down while turning the engine, or do you have to really crank on it to get past the hard spots?

I tried - but feels like a dead stop. Do not want to force.

I did not test the deck height on the right side after it tested perfect on the left side.

That's not good news, sorry to hear this. With no rocker arms installed and chain tensioners or mechanical device keeping tension, rotating clockwise, there should be no hard spots and definitely no "stop dead" spots. I would start with loosening up the suspected side first and see if things clear up so you can start to pin-point the problem. Deck heights and TDC piston to head clearance measurements on all 6 at this point should be performed and documented.

Putting an ear ( wife's ) against the case , it sounds that it might be # 4 con-rod touching the side of the case. Turned free on dry run before torquing the case.

Does this make sense ?

Also received extra cylinder base gaskets to install if it is a deck height issue.

Will use the endoscope next week to confirm - taking a few days off

After taking some time off , I decided to again visually inspect everything I have done so far with a flashlight and endoscope. I have convinced myself in the last weeks that if someone messed up , it would be me , and not Ollies.

One of the first things I did , was to look inside the case at the #4 con-rod , and lo and behold ! The left chain slipped partially off , riding on only one set of teeth, making contact with the rod ( #4 - suspect No 1 ) about 30 degrees clockwise from TDC.

I will wait for my garage to cool down a bit ( yes, I got kicked out of the living room ), and take care of this.

I hope it is something as simple as this that caused me many hours of frustration , and not any thing serious.

Ironically , the tension I kept on the chains made sure it stays on one set of teeth. Must have slipped off a while ago.

Don't feel too bad Errie, that chain over half the sprocket thing is a common mistake. Just be glad you caught it before really trying to turn the motor over.

Chain released and re-fitted - crank turn free ! I checked the torque on all the nuts , and re-alligned the sprockets.

This was a good good night !

Camshaft timing
 

Wayne's book " How to rebuild and Modify 2003 " p167 says to tighten camshaft nut to final value , and then begin clockwise turn 360 degrees. Then , remove nut and dowel pin , make adjustment , and torque to final value.

Is this correct ?

To torque to 110ft/lb using a tool that wants to slip off all the time , can be done if you have an extra hand. I busted 2 knuckles , and scared the crap out of the cat - doing it only once !