Because I don't have the proper tools to remove the crankshaft sprocket I checked the key-way per ivagp's suggestion through the cylinder one glow plug hole. it's very clearly TDC when the crank sprocket is locked into position with my metalnerd tool.
I called Dieselgeek yesterday to inquire if they've had any problems with their timing belt kits and/or alignment tools. No problems.
I replaced the timing belt this morning being super methodical and attentive, making sure to tension the water pump side of the belt. I then triple checked the alignment (rotated the crank two times around) then placed the cam and crank alignment tools, and they slid in easily and smoothly all three times. I tightened everything down to proper torque and started the car- same old thing, rough idling around 500rpm and no throttle response. Torsion was 0.5, timing very advanced, etc., etc.
Then I decided to move the cam pulley to experiment with different Torsion values. I moved it to the position shown in the picture below, started the car and it fired right up, settled into a smooth idle at 903rpm, AND the throttle worked perfectly, revving smoothly to 3000rpm. The torsion value showed 4.4! ?
Anybody? Should I move the cam pulley a whole tooth? If I move it one tooth the cam pulley bolts will be at the edge of their slots- is that OK?
[/IMG]