HELP!! What did I break??!
 

Hello, I am new to the forum and it's unfortunate I had to post my first thread on a negative note. I am in the process of restoring a 1977 911s.. Long story short, while replacing the points and adjusting the gap I used a large wrench to turn the motor from the crankshaft pulley (to get it right at the highest point of the lobe on the hexagonal shaft of the distributor)... after setting the gap I put the cap and rotor back on and tried to start the engine and what I heard whas a loud CLUNK!! but the engine ran for a few seconds, with LOUD CLUNKING NOISES!... I realized I had left the wrench on the pulley and as the engine turned over it made it hit the side and loosen up the center bolt holding the pulley to the crank..

.. I put everything back in order and re tightened the pulley, but now the pulley rubs against the alternator housing.. and not only that, but it became "frozen" for a few tries, and after turning it some more by hand it will now start back up but there are strange clinking noises while idleing..

MY QUESTION: What could I have broken internally??.. I am thinking the worst, but is it possible for the sprocket that runs the cams to have jumped a tooth??... am I over reacting and could it just be the pulley got bent??.. I have come to this forum countless times and recieved GREAT technical advice, and given that this is my first Porsche, any and all replies will be deeply appreciated.. Thanks!

-Alex

Maybe a bent pulley as you mention. The bolt could have bent and you may have sheared the pin that indexes the pulley on the crank.

Take the pulley off and inspect pin as JP suggests. I'd probably use a new bolt.

Is it a single belt pulley?

I will start by replacing the pulley and the bolt as well.. The index pin looks intact it did not shear off.. And yes it is a single belt pulley.

*fingers crossed* I hope the extent of the damage ends with the pulley, I will post an update after the pulley is replaced.. thanks for now!

So after removing the crankshaft pulley I started the car and the noise is STILL there!! :confused: ... it almost sounds like a spun connecting rod bearing.. ??.. a loud, constant ticking sound that does not go away even if I apply load on the engine... any ideas on where this sound could be coming from??

You started the car without the pulley connected?

Or noise still there with a new pulley?

I don't suppose it's something simple with the wires/distributor cap....

Without the pulley connected.. thinking that the sound was coming solely from the pulley rubbing against the alternator housing. But there is STILL a loud ticking noise :(

Can you tell where the ticking sound is coming from? Timing chain housings? Distributor? Valve covers?

The sound is hard to pin point because it is pretty loud.. But seems to be coming from the valve cover :/

Personally speaking, I wouldn't run the engine again until you diagnose the problem. The motor should probably be dropped so that you can remove the timing chain covers, valve covers, and the engine mount to conduct a proper inspection. Consider posting this thread on the engine rebuilding forum as well for more suggestions/input. Good luck!

Can you post a pic at this stage (annotated)?

Thanks for the great advise guys!..

UPDATE: So I did a partial drop of the motor and removed all valve covers to inspect the rockers and I BELIEVE to have found the source of the noise.. The rocker arm for the exhaust valve on cylinder #6 seems to not be returning??!!.. The rocker arm has play of about 1/4" if I rock it back and forth.. So this is leading me to believe to be the cause of the loud chatter noise..
I will post pictures later today

What can cause the valve not to return? or Close???!!.. any Ideas?.. broken spring? Bent valve?? :/

A bent valve may not be out of the question, but a broken rocker arm sounds more likely. I honestly don't know enough about the internals of these motors to guess/opine on what may be happening here. I can't visualize how a wrench on the pulley/loose pulley bolt could cause a rocker issue, but that doesn't mean it didn't happen. Any other rockers loose?

Im thinking the same. I dont see how the wrench on the crank pulley bolt, which simply broke the bolt loose, could disturb or have damaging effect on a valve or rocker arm.. unless somehow it caused the cam timing to be out of whack..

..at this point no other rocker arms have the same symptoms, I will turn the motor by hand and check all the valves to see it they all return/seat properly.. I guess I will also check the timing on the cams also to see if by chance it jumped a tooth.. btw I already removed the timing chain covers and they seem to have proper tensioner, and the guides are not damaged.. Thanks for now!

That sucks big time but we can put it under a C'est la vie... statement.

I just did my valve adjustment yesterday, whenever the valves to be adjust were close, there was a play side to side but it was more like 1/16".

This may sound funny but since you got the cover off, why don't you pretend nothing happened and go through a full valve adjustment and see what happen.

In the case of it being a bent valve, could I get away with rebuilding just that one head with the affected valve? (possibly the guide as well).. This would, of course, be after finding the real reason for the bent valve in the first place..

-Alex