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how do you ensure tdc on cylinder one?

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I have a small metal rod that I sit down in cylinder one for testing purposes. You can see when you rotate the crank it will get to its highest point. I usually do about 10-15 rotations so I can get a feel for exactly when it starts to go back down. Best way to ensure TDC for Cylinder 1 in my experience.
 
Yup with them line up perfectly on the cams. But when the cylinder is tdc my main pulley is maybe a half cm past the tdc on the timing cover.


Line the engine up with #1 TDC. this mean the crank pulley should line up on its corresponding mark. Which from what you are saying is that your cam timing is off. You always ensure the crank is lined up first, dont try lining it up by the cams.

Time to pull the head.
 
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