Out of options... ready to part the damn thing out [vid]

[Andy348]

This has been happening since last summer. I am tired of this. I posted about it last year, saying that the starter seems to crank the car over once or twice and then hit something. While it cranks it sounds like something is loose, hitting something. Here is an example. My dad cranked it over twice, first time it hit and died quick, second time not as loud but still dies.

http://s1252.photobucket.com/user/Andy348/media/VID_20140530_154012_zps72f409cc.mp4.html

Sometimes it'll crank once and then clunk (die), other times it'll go 5-6 times.

I have replaced the flywheel with a used one that I got resurfaced, and I just put in a new starter today.

Here's what makes it even crazier:

The car will not clunk/die without compression. That means without the spark plugs in, or without the head on, it will crank over fine and not have any problems. As you put the spark plugs back in, one by one it gets progressively worse.

The car will start and run fine if it is push started.

Any ideas?

[Vivek]

Proper power going to starter?

[jlevie]

My first suspicions would be a bad starter, a problem with starter main power connections, or a problem with the engine or battery ground connections.

[ahlem]

I had this when the bushing at the nose of the starter was dying. Pull the starter and turn the motor by hand and look at all the teeth to check for possible issues. Both the flywheel and starter gears.

[Andy348]

First starter was rebuilt, then rebuilt again, then replaced today. No change.

Power problems I've been suggested before, but this will happen intermittently - sometimes I can crank it for a solid 8-9 seconds and then it'll physically clunk and be done, other times it happens very quickly. I have a new battery, rebuilt alternator, and have tried it jump-started with numerous vehicles.

The flywheel teeth are fine - the first one that I pulled out looked fine, and the new one that I just put in were definitely fine.

I will try to bypass the whole power issue by giving direct power to the starter and see what happens.

[mpowerful]

How does the car run when it starts? I ask because its possible one or more injectors are leaking and flooding cylinder/s causing it to hydrolock. Seen it before.

[Andy348]

You guys might be on to something. Just tried to jump both the bottom post and the power post with another battery, and it works and cranks fine.

So now I guess its time to inspect the starter wiring? Is there a relay/fuse that I should suspect? Any starter wiring diagrams I can take a look at?

[Andy348]

@mpowerful: might be on to something too.. it runs pretty darn well, but its got intake leaks so its hard to be completely sure.

[DesertBMW]

wrong transmission alignment to the engine block. You installed the transmission without dowel alignment pins present in the engine block. When no compression, starter has no problem spinning the engine. When compression then load forces the starter gear out of the flywheel gear at one spot where runout is too much. This causes starter gear to lock itself against flywheel gear peak.

Why didn't this noise appear before, because it took time over heat cycles and load vibrations for transmission to move slightly out of alignment.

[Andy348]

Things got even weirder today.

Put spacers between the starter and the mounting points on the block, assuming I've forgotten a spacer. The car worked fine, almost started (without AFM/ICV/etc).

Then I retightened it and it stopped working.

Checked ***mpoweruful's fuel idea, and it turns out one cylinder IS throwing fuel like nothing else. I unplugged all the fuel injectors, it's still pissing out the second cylinder. I switched out that injector for another one, and still pissing out the second cylinder.

Oh, and hooked up a battery to the two posts on the Starer (like I said I did last night) and today it jammed, when yesterday it didn't.

Brb lighting the damn thing on fire

[mpowerful]

You mean my fuel idea. Change out the two injectors. Or if you wanna test for sure remove the fuel pump relay and try it.

[Andy348]

Sorry, wrong person. I'll do that tomorrow. If they're shitty I'm buying some new ones from you tomorrow.

Thank you! I will attempt.

[mpowerful]

Hahaha cool

[jlevie]

The only thing that makes any sense with respect to the injectors is that you tried two bad injectors. The injectors are fired as two banks of three, so a problem with wiring or the DME would cause problems with three injectors. Not just one.

The ring gear, flywheel, transmission and starter alignment can be fine. But if the pressure plate bolts are too long they will prevent the ring gear from fully seating on the flywheel.

[mpowerful]

I have personally seen this happen with one stuck open injector. It will hydrolock a cylinder easily.