You guys called it. Redid the job checking that the #1 piston was at TDC by using a long match stick and confined that at the same time the notch on the crank pulley matched the seam on the block. Confirmed that #1 valves were closed when the camshaft white dot was aligned with the nub on the rear timing cover case. Took off the distributor cap and confirmed that it pointed to plug #1 when the pulley white dot matched its mark. Reinstalled the timing belt and put it all back together (again).

Fired it up and it ran! Then had some hiccoughs and died.

Realized I had taken a vacuum hose off for better access to get the distributor cap clips back on. Reinstalled the hose and it is running smooth now.

I don't know when the timing belt was last replaced but the old one must have run for at least 12 years and upwards of 100,000 miles before it failed.

Thanks again for your help.

Brian Mee

1991 240
1990 240 DL (parts)
1992 945T

if you confirm that the crank and cam shaft are both lined up to TDC then you have advanced or retarded the rotor placement as set from the intermediate shaft.

set you timing to TDc then remove the diz cap and see if the rotor is pointing at the middle of the #1 plug spot.

i will wager it is not

The prime suspect is belt timing! You need to set the engine at TDC with both #1 cylinder valves closed and check the intermediate and cam shaft timing marks on the engine / pulley's.

This is real easy to get wrong even if you have done it a dozen times in the past.
Dan