UPDATE: Found the culprit. See pictures below.

My C4 project has been stalled for 4 months after I reinstalled a refreshed short block with new crank and timing set. I should have known the call from the machine shop back in March questioning me how the opti is driven spelled trouble. See my saga below but during start up, what is the estimated timing the ECM is setting? The crank hub was removed so I found TDC and made a mark about 20 degress before it expecting to see it close when I turned the car over. Using an old school timing light its about 30 degrees before that mark! I can't imaging it being in the 45-60 before tdc.

After reassembly I had a no start condition and then chased a DTC-41 code for a few weeks. With all the diagnostics I was doing replacing parts, one of the coil connectors went partially bad (a biotch to find). Well I fixed that and have spark to all the plugs. I was excited to fire up the new motor but still no start. It just sounds bad turning over like its trying to hydralock. I verified the plug wiring was correct multiple times and had a mechanic friend double check. I pulled all the plugs and they have gas on them but not soaked. No codes are being set. I am guessing a timing chain is off a few teeth.

Has anyone gotten the timing cover off with engine in the car? Doesnt look like there is enough clearance to pull the hub off. Any help appreciated.

 

Maybe just pull the opti first. 92 uses a spline drive. It should only go on one way but may have been forced on and is now out of time. Timing gears, if they went dot should be fine. The crank is keyed for the timing gear so it’d be pretty hard to have the timing set that far out. No key for the balancer hub as you found.

 

Thanks. Yeah already pulled opti. The spline drive looks damaged on the double tooth and could have been installed incorrectly. I installed a different opti (have 4 of them) and looked like the timing was still too far advanced but without any fixed markings its difficult to really know. All a guess. I need to reinstall the plugs and other 7 wires to see if that was the issue. Sux that I cant see behind the timing cover

 

Glad to report that my ignition timing issue has been resolved. It turns out the opti shaft was indeed damaged enough to slip into the cam timing gear sprocket misaligned. Reinstalled the opti with proper orientation and the engine fired right up!!

 

Good find!