Why engine won't run?

[morbid]

Greetings to all fellow members. Long time since last visit...

I have a '83 engine to which I made a major rebuilt in 1998. Not due to engine problems, but because parts prices were cheap then. Then I used the car until September 2000, because I had a serious accident in my job. I started to use the car again by February 2001 until November 2006 when I stopped the car because the underbody went real bad. Took the engine and transmission out of the car, and kept them in a safe place. So I started to use a 1984 944 I've already had, and drove it until 2007, when clutch went out. That car was kept the same place the other engine and tranny.

I sold the short block of the '84 in 2009, thinking to swap the '83 engine on it in a near future. December last year, I disassembled the engine, and looked very clean inside. I've always used synthetic Motul engine oil, and RedLine Water Wetter coolant additive in it. The body of the '84 car is in better shape than the '83 one, but not as good as I want it to be. So I thought that rebuilding this engine again would be a little waste of money. Today the rebuilt kit cost double the price. As the engine was in a very good shape I just bought a new full gasket set, assembled the engine again, and installed it in the car by March... I'm doing this very slow, because my full time job and other responsibilities didn't leave me enough time. But I love the 944.

I ordered some other parts needed, like timing and balance shaft belts, tensioners, rollers, motor mounts, master and slave clutch cylinders, and some new sensors. Last week, I noticed I did not replaced the lower balance shaft bearing case for the p/s pump, I kept from the '84 engine block. That happens went you go on a project, about 6 to 7 years after having the idea!

Today I thought to install the timing belts, connects the wires and hoses left, and if the engine starts and runs well, replace the p/s unit with the manual rack I still have. After reading a lot of posts about p/s vs manual last night.

Unfurtunally, for a reason I don't know, when I installed the timing and balance belts, and tried to tight the crankshaft bolt to its torque specification, the engine stucked not rotating when the bolt started to fasten... Strange, because I suppose to use a flywheel stopper to torque the bolt.

I made a test and put a little aluminum washer (one from the camshaft bolts plug) over the bolt, just between the crankshaft bolt cap and crank; and the bolt got fasten rotating the engine without problems. It's like for some reason the crankshaft bolt cap put pressure on something that won’t permits that crankshaft to rotate freely.

Any comments????

My worst nightmare is having to take the engine off and tear it down again... I feel that the wasting of money I was trying to avoid, happened anyway. My love for this car is becoming hatred.

[grendiers]

Sounds like the oil pump sleeve might be getting stuck on something, not going in straight? Jamming up against the oil pump?

[morbid]

Originally Posted by grendiers

Sounds like the oil pump sleeve might be getting stuck on something, not going in straight? Jamming up against the oil pump?

I thought about that, and took off belts, tensioner, rollers, and timing cover to verify. Oil pump sleeve was OK. Tried with another one, the same thing... Maybe the wrong thing is there at the oil pump, but how do I know?... Replacing the pump? Whoho...

[mytrplseven]

Are you 100% sure the cam timing is accurate? I'd hate to think that you were fighting against valves hitting the pistons.

[thomasryan]

777 is thinking down the right avenue and which way install the timing cog on the crank?

Could not find a picture on this machine but I believe the lip goes out and yours might be binding on the cover.

[morbid]

Originally Posted by mytrplseven

Are you 100% sure the cam timing is accurate? I'd hate to think that you were fighting against valves hitting the pistons.

I'm 200% sure, since there are two belts... Since the first time I installed the timing belt, I used a short bolt directly to the crank to rotate the engine two full turns to ensure cam and flywheel stills on their timing marks. Then, when I installed the balance shafts belt I did the same: two full turns, and the timing marks on cam, flywheel, and balance shafts sprockets still on theirs marks. The cam and pistons are not interfering. Every timing in the engine is right.

It's when I put on the original crankshaft bolt with its washer cap, and proceed to torque it to its specification, when the engine stuck won't rotating... Like the crankshaft bolt it's pulling the crank in front of the block sticking it on something.

Since I rebuilt my engine on 1998, I have repair 4 more naturally aspirated engines from different years (one '85.5, two 86, and one '87) without any problems or comebacks (my home town is a little municipality and that cars are not very common in this area). That's why I'm very confused.

I'm not an expert in this 944 naturally aspirated engine because of this... If I fix this thing with your help, I'll become an expert.

[thomasryan]

Do you have the outer lip on the timing belt cog facing forward?

[morbid]

Originally Posted by thomasryan

Do you have the outer lip on the timing belt cog facing forward?

I've been surprised when I realized I was trying to solve this problem with my eyes closed or flashed... I have the Haynes manual for this car, which I used in every job did on this cars. As I mentioned, I have worked with several of these engines, some years ago now. I'm a licensed automotive technician in Puerto Rico, precisely since 1998. I worked for Western Auto / Advance Auto Parts for 6 years. I currently work for Pep Boys Auto Puerto Rico for 5 years. We have available here Mitchell On Demand to make referrals. And thomasryan just point me the problem ... I was putting the crankshaft timing sprocket in the wrong position!

Well... I am far from being an expert on these engines. But if I will be near of being an expert in this engines sometime in my life, it's thanks to thomasryan. Thanks thomasryan and fellow members of this forum! You have returned the faith and love for my 944.

[morbid]

Originally Posted by morbid

... I was putting the crankshaft timing sprocket in the wrong position!

"...That happens went you go on a project, about 6 to 7 years after having the idea!"...