Pinzgauer again
 

I got about 1700 miles out of my engine rebuild before I ran into trouble last Friday. I was 89 miles from home headed up to do some off roading and over the course of five minutes I lost power. As this started to happen there was a chugging sound that was in sync with the motor rev. I started to think I was loosing compression in a cylinder. Then I could go no more, the engine ran really rough and I couldn't get it to rev up at all. Step on the accelerator and just more smoke. So I had a 89 mile tow bill back home.

The IP timing belt appeared loose: http://youtu.be/0-IJIueVuWg
So the next day I checked the timing and it was at about .58mm. I tightened the belt up up a bit and reset the timing to .90mm. Maybe it slipped a notch.

Here is me trying to start it cold, still really rough: http://youtu.be/oRWDgMSjjzA

So now I am thinking bad thoughts...Did I put too much oil in it and cover the squirters? Did the front timing belt slip a notch? Did an injector go bad? (I had them rebuilt and tested with the engine rebuild).
If it was an injector, I loosened one at a time, no real difference.

So what do you all think?
My thought is to take it apart and check the main timing. If that is right, my next thought is to pull the head and see if the valves and pistons are okay.

Pistons will usually be OK if it hit at low RPM, the valve buckets are suspect, and get checked for cracks. unusual valve clearance might offer a clue.
can you get the cover off to see if the water pump moved or took a dump?

Yep, yesterday I took a look at the timing belt and it looked a little loose with the cover pushed back a little bit. Today I took the TB cover off. It looks fine and the WP is there and spinning over as you'd expect. Tension seems fine now.

I got the head off today, this is what I found. Photo of the original here too. All of the rings have bits missing!

[IMG]http://i1311.photobucket.com/albums/...pssdxbh0fx.jpg[/IMG]

[IMG] http://i1311.photobucket.com/albums/...psqy2cyldn.jpg[/IMG]

[IMG]http://i1311.photobucket.com/albums/...psjei0dppz.jpg[/IMG]

[IMG]http://i1311.photobucket.com/albums/...psa4una2jw.jpg[/IMG]

Weak.
what gasket / bolts did you use?

The gasket in the photo and Raceware studs.

Wow, I can't believe that happened. I'm curious about the head gasket.. Was the bores of the engine block larger diameter then the opening of the steel sealing ring of the head gasket?( head gasket protruding into cylinder bore)

50some ft/lb and no retorque?

50ft/#, i did retorque.

Not sure. Didn't protrude enough to get under the lip of the bore to pull it off the block though.