Just so I am straight on the chronological order of events;
Van brake down and you replaced; battery, alternator and intake manifold gasket.
Then the Van still would not start. What lead you to replacing the battery, alt, IM gasket?
Did you ever check for spark before you replaced the timing gears and chain?
Was the timing gears and chain something you did after the battery, etc?
There is a chance that your engine is equipped with a Non-Interference safety mechanism.
This means if the timing chain fails or stretches it stops the engine before the valves can hit the piston and damage the motor.
I have not found a definitive answer on this yet and will get an answer from a higher up expert if need be.
However if you are getting spark to the coil, it should be sparking and I am assuming you are turning the van over, so if there was any interference from the gear being out of line, you would have heard it.
Also, the timing chain cover should drop right into place when installed in relation to the crankshaft marks.
Are you sure the motor was a TDC and the can and crank were aligned up? Sometime after installation it is a good idea to turn to assembly 10-12 times and re-check alignment. If the is a chance it could be off by a tooth, it might not hit pistion to valve until its running and the valves stretch. Not to mention performance issues.
I you don't have it totally reassembled, you might want to consider re-checking the cam to crank alignment. I realize it is hard to mess up but rotating it can make a difference as I have found out myself.
I will watch for your reply and check into a few more things and if I can't figure it out I will ask someone I know who is A Ford wiz. He is hard to get a hold of but I will get in contact with him by tonight if necessary. I am actually going to try getting hold of him again right now.
I don't want to give you any answers that I am not fully 100% and move in the wrong direction and waste time.
Please consider a to help us answer more questions.
Wednesday, August 24th, 2011 AT 8:06 PM