Engine Mechanical problem
1992 Suzuki Sidekick 4 cyl Four Wheel Drive Automatic 110, 00 miles
I rebuilt my engine. I had NAPA rebuilt the head. After putting it together, I put on timing belt and made sure the alignment marks on the Crank shaft and CAM shaft are aligned. I go to TDC and adjust 1, 2, 5, 7. Then I rotate 360 on the Crank shaft to adjust 3, 4, 6, 8 valves. All according to shop manual. But I notice that number 7 has a large gap (approx 1/2 inch) between rocker arm and valve I can move the rocker arm that much. After adjusting 3, 4, 6, 8, I rotate again to TDC, now valve 2 has the large gap. And offcourse engine wont run. I know its not a good idea, but I can get it started by changing the distributor position approx. 90 degrees and I get a lot of black smoke, and the engine sounds like a train. I know the sound is the rocker arms (that 1/2 inch gap). My question is where did I go wrong. I set everything at TDC, Crank shaft, CAM shaft, Distributor rotor. I set everything according to the book, Yet every thing seems to be off. Please help.
I prefer to check each valve individually, with the two valves with excessive clearance, rotate the engine until the suspect valve is closed and the piston is at TDC for that cyl, remove the plug and a long pencil in the plug hole resting on the piston will stop moving with the piston at TDC, you do this slowly and carefully, if you have no further adjustment at this point, yo will more than likely have a broken vale spring, a leak down test may indicate a poor valve seal as a result, do not run as you may do serious damage.