Also, to the questions from Anders and ngoma asked above, exact answers from the mechanic will help:
What is the numeric timing setting the mechanic used?
And is he certain he didn't time it 180 degrees off?
Even if the reading on the dial is correct, meaning the IP is timed correctly to the crankshaft, you still can be 180 out on the camshaft. Does he understand how that works?
We're not trying to question his competence. However, it's very common with these engines for a skilled and experienced mechanic to do a lot of excellent high quality work on mechanical reconditioning, but then get tripped up on the final steps with the timing process. What makes it tricky is that it is very specific, and demands patience and a real understanding not just of the technical procedures involved, but of what they are fundamentally intended to accomplish. Those who don't try to reach that understanding are always tempted to take shortcuts on the steps, not realizing why they are necessary. This is why the first questions we all asked were about the timing process used.
