Still can't get this POS into time.
I have crank at TDC, verified through the spark plug hole, the crank keyway at 12:00 and the crank pulley even has a mark, which is lined up.
Got the valve cover off, properly lined up the cams, using a flat bar and some feeler's gages to make it precise. Piece of cake so far.
Problem seems to be with the ZTec variable exhaust cam. It'll start and run, but won't stay running under 1500 rpm and feathering the throttle. I've had this timing belt on/off at least 15 times now (I'm persistent) and tried every blessed combination physically possible.
I have moved the exhaust cam timing belt sprocket (keeping the cams themselves locked into position with the tool) from its full aft "resting" position against its spring pressure one tooth at a time until it has moved its full amount of possible travel. It runs worse as I advance each additional tooth until it won't start at all at its most forward possible position. So, the at rest position is best, but not good enough.
So, i went back to leaving at its "rest" position (spring in the sprocket assembly makes it return to this spot) and tried varying the crank one belt tooth in each direction. No joy.
Each time, I turn the crank 2 revolutions and VERIFY the timing stays aligned. It does. Then, when I reassemble and start it, it won't idle. Tear back into it and the exhaust cam IS NOT IN LINE, it's off by ~1/2 wrench flat on the cam, maybe 15 degrees. I just don't get it! So, I remove the belt again, line everything back up meticulously, reinstall the belt, set the tensioner, rotate crank 2x, checks good, lines right up until started.
I'm throwing in the towel at this point. If anyone has any ideas, I'd love to hear them.
Is it possible that the variable valve timing solenoid is stuck open? I would think its duty cycle is "closed until energized" but if it is "open until energized closed" I could see that being possible. It was running/idling great when he drove it in. Just needed the WP changed and the timing tensioner. The only thing I did was disconnect the electrical connector to that solenoid to get the valve cover off. Wires look good and the pins aren't corroded. Oil runs out of the exhaust sprocket oil cover, when removed, but it isn't "full". I haven't removed that sprocket because the spring tension returns it to "rest".
http://teamzx2.com/showthread.php?t=117 leads me to believe I may have to remove the sprocket and re-lign it up. Could be why the exhaust cam is always out of alignment after I start it. Nothing else jumping out at me. Off to buy Torx sockets.
Anybody?? Bueller? lol