Thanks for the well written and detail oriented story, the more information we get, the easier it is to help! The easiest way to tell top dead center is to remove #1 spark plug, turn the engine over by hand until you hear the whoosh of compression and then turn slowly until you get the piston all the way up. You can buy the alignment tool online from the most popular online store that starts with an A for $20.00 which is the easiest and fool proof way or if you have a scan tool that has a power balance capability to identify cylinder contribution, pull a plug wire on a particular cylinder and verify on the scanner that it coincides with it, if not loosen the bolt and turn the synchro to see which way you need to go, trial and error but it will get the job done. As far as a misaligned synchronizer causing a blown head gasket, I’ve never heard of that in my 27 years as a dealer tech! These engines pop head gaskets all of the time! In my opinion it was probably on it’s way out, you just happened to be the lucky one to have it happen while you were working on it. Hope this helps!
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Monday, June 24th, 2019 AT 6:11 PM