Finally able to get that crank off. Purchased M8 1.25X50MM bolts and using the tool and a 12" breaker bar I used a Yakima 48" crossbar as a cheater - I WIN! Yes, I took photos while I went.
Installed the New Water pump, but that inlet would not come off - just an o-ring gave me the hardest time today. But alas, I WON again and got past that part. Then I broke a bolt installing the inlet part that attaches to the water pump. Drilled that out and was able to get a bolt and nut on it - not too worried there because it was so hard to take off. BTW - the weap hole for air was leaking fluid on the water pump and I am glad I replaced it.
Am I glad I am doing the timing belt - not right now. The belt showed some wear on the outside - some dry cracking, but no threads torn like Pete.
To the Install - What in the heck is going wrong here
I still do not quite understand how you can start at "roughly 50 degrees past TDC and then install everything and it comes out perfect??? After 3 installs, I do not think I have it. And after the 3rd time walking in the tensioner 2 bolts I think I broke-twisted one of those too
but I did not take it off to be sure - its really tight walking that thing on. The bad part about purchasing a new tensioner is that every time you test it and do not get the timing - you would have to take it out again and find a press to compress it.
Well, I am chalking it up to tired and I am done for the evening - perhaps in the morning I will check the timing and only look at the cams and not the belt as it does not matter what it says. This is when its nice to have a buddy to check things, which I do not have right now or to point out that you missed a step. I can almost write the FSM by memory and I still don't get it.