The story does have a happy ending.....
Well, the story begins here:
http://www.m5board.com/vbulletin/e3...en-working-your-car-you-need-read-thread.html
It ended today when we had the car towed back to my house so we (WingsAA, or Brain, from Ohiobimmers.com) could tear it down again to find out that I installed the flywheel incorrectly. I did not line it up with the dowel to ensure it was in time with the crank. I am a moron, an idiot, whatever, you would think I would have known this by now. This is my 4th one, but must have gotten VERY lucky on the other 3. Once we installed it correctly and put everything back together, the car fired right up. Lesson learned. From the time it was unloaded from the truck to the time we pulled it out of the garage it only took us 3 hours total. Not bad. The problems had NOTHING to do with hooking the battery back up with the ignition on. Sorry for leading the witch hunt guys. There was a TON of useful information in that thread though.
Pictures......
This shows what the back of the motor looks like with the flywheel removed. You can see the output shaft from the crank surrounded by the rear main seal. The red arrow points to the dowel pin on the crank. The other arrow shows where the pilot bearing will go.
This shows the one larger bolt hole that the dowel fits into. This view is of the back side of the flywheel. The side that goes against the crank/motor.
This is a picture of the front side of the flywheel, the side that the clutch attaches to. You can see the 2 little half moon marks that indicate the bolt that has the larger hole that the dowel should go into to correctly line up the crank (circled). The arrow is pointing to the pilot bearing installed.
This picture shows WHY this is so important. The Crank Position Sensor reads the missing "tombstones" as Raza called them, to tell the ECU that the crank is at Top Dead Center. I had the flywheel 2 holes off, so it was giving the ECU incorrect timing figures. That is why the car would not start.
All in all, it was a very informative weekend full of headache and worry. I am so happy and relieved we found the issue. THANK YOU to Raza, Steve, Peter, Chris, Brian, the other Brian, Mike, the other Mike at N.E. Motorsports, and to everyone in the other thread for the suggestions and kind words.
Phil has his car back, running perfectly. I'm sure no one is happier than him. Once again Phil, I AM SORRY. Thank you for being so wonderful about the whole thing. Chris and I were just talking about how we would be in your shoes. You are a trooper!! Thank you.
Now, commence with the making fun of me, I DESERVE IT. No flamesuit, I deserve to burn.
Well, the story begins here:
http://www.m5board.com/vbulletin/e3...en-working-your-car-you-need-read-thread.html
It ended today when we had the car towed back to my house so we (WingsAA, or Brain, from Ohiobimmers.com) could tear it down again to find out that I installed the flywheel incorrectly. I did not line it up with the dowel to ensure it was in time with the crank. I am a moron, an idiot, whatever, you would think I would have known this by now. This is my 4th one, but must have gotten VERY lucky on the other 3. Once we installed it correctly and put everything back together, the car fired right up. Lesson learned. From the time it was unloaded from the truck to the time we pulled it out of the garage it only took us 3 hours total. Not bad. The problems had NOTHING to do with hooking the battery back up with the ignition on. Sorry for leading the witch hunt guys. There was a TON of useful information in that thread though.
Pictures......
This shows what the back of the motor looks like with the flywheel removed. You can see the output shaft from the crank surrounded by the rear main seal. The red arrow points to the dowel pin on the crank. The other arrow shows where the pilot bearing will go.
This shows the one larger bolt hole that the dowel fits into. This view is of the back side of the flywheel. The side that goes against the crank/motor.
This is a picture of the front side of the flywheel, the side that the clutch attaches to. You can see the 2 little half moon marks that indicate the bolt that has the larger hole that the dowel should go into to correctly line up the crank (circled). The arrow is pointing to the pilot bearing installed.
This picture shows WHY this is so important. The Crank Position Sensor reads the missing "tombstones" as Raza called them, to tell the ECU that the crank is at Top Dead Center. I had the flywheel 2 holes off, so it was giving the ECU incorrect timing figures. That is why the car would not start.
All in all, it was a very informative weekend full of headache and worry. I am so happy and relieved we found the issue. THANK YOU to Raza, Steve, Peter, Chris, Brian, the other Brian, Mike, the other Mike at N.E. Motorsports, and to everyone in the other thread for the suggestions and kind words.
Phil has his car back, running perfectly. I'm sure no one is happier than him. Once again Phil, I AM SORRY. Thank you for being so wonderful about the whole thing. Chris and I were just talking about how we would be in your shoes. You are a trooper!! Thank you.
Now, commence with the making fun of me, I DESERVE IT. No flamesuit, I deserve to burn.