FYI: I own a 98 Mystique with a build date of 4-97. I believe this is the original engine but I'm the 2nd owner so I'm not 100% sure.
I recently had to redo a timing belt installation that was done incorrectly at a shop. When I tried to align the cams I substituted a 3/16" thick, mending bar (~12" x 1-1/8") from ACE hardware to lock the cams in place of the Ford specified tool. I set the crank @ at TDC using the marks on the pulley/oil pan and also used a rod inserted into cylinder #1 to verify.
When I attempted to lock the cams, I couldn't get the mending bar to slide into the cam slots. It seemed like the centerline of the slots were below the deck height of the head. I didn't loosen the cams from the pulleys and ended up "eyeballing" the alignment as best as I could. I finishing the job with no problems and the engine runs fine.
I would like to open things up again in a few weeks and set up the cams correctly. I ended up buying a cam locking tool & crankshaft TDC pin from OTC (http://www.amazon.com/gp/product/B00...ls_o00_s00_i00), but the cam tool looks very similar to the bar I already tried to use.
My question is this:
1. Did I make a mistake in my procedure?
2. If I didn't, are there different kinds of camshaft locking tools available for the ZETEC? It seems like my cams need a locking tool that extends below the head deck.
Any help would be appreciated!