This is in reference to my earlier post on the serpentine belt that killed my B6304 (see post id=498946). I got the ALLDATA information on this engine for both the timing belt replacement procedure and the Head R&R.

I have pulled the plugs, (Good Bosch Platinums) and removed the front covers, serpentine belt tensioner, and then checked the timing. I can get both the top pullies to line up with their marks right away, but the crank was 18 teeth off from where they lined up. Looks like the belt jump was on the crank.

I pulled the tensioner off and reset the timing according to the marks, but I still have interference when trying to rotate the engine. (this existed before I moved anything!) What has me stumped right now is that the #1 piston is not all the way to the top when all the marks line up. I don’t know if they are supposed to be or not though.

In the ALLDATA print out it shows a special tool that is inserted into the block after removing the starter that locks the engine in the proper position for setting the timing. It describe the process this way:

Align timing mark on crankshaft,

Remove starter motor,

Remove protective plug

Mount crankshaft locking tool # 999 5451 or equivalent

Turn crankshaft counterclockwise until stopped by tool

The notch that I am lining up on the crank is a very very small notch in the toothed gear on the rear top of one tooth. I am wondering if the problem could be in some way that this gear could have "slipped" or rung off a woodrif key so that the mark is no longer valid. It is appropriate to note that the engine locks up at the very same points now as it did before attempting this timing reset. Most likely it is at TDC on some of the cylinders.

Needless to say, the pistons are hitting something , (one of 24 somethings I think) but I sure would like to know that I was on the mark before tearing down the engine. So the big questions of the day are:

When the timing mark on the crank is lined up, is #1 on TDC? Or is this some arbitrary mark used only for process of setting the timing?

Also, how important is it to have the special tool # 999 5451? And what would a home made one look like?