Hot Cranking Problems on the new 2L 16V

[Bill.Scarince@tenneco-automotive.com]

Among the usual new-engine gremlins, I have a strange one.  When the engine is
cool or cold, it cranks and starts fine.  However, when hot, like if I stop to
get gas or stall at a light and try to restart, it cranks like a dead battery.
When it cools for even 30 min. or so, it's almost normal again.   I'm suspicious
that the new compression ratio has something to do w/this.  Here are some facts
and observations to consider:

The engine is a 2.0L 9A block w/a 1.8 16V head, both all stock (as far as I
know).
I don't know what the new compression is (loaned my tester out).
The battery is fully charged, and the alternator puts out about 13.8V when
running.
When cranking a hot engine, the battery cables get so hot they smoke.
The cranking voltage measured between the battery posts is around 11V.
The cranking voltage measured between the lug on the starter and the ground
cable just before it bolts to the bell housing is about 7 volts.
The battery cables are stock.

So obviously, I'm pulling some serious current to get that kind of heating and
voltage drop.

Has anyone seen this before?

Bill



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