I have had a dig around in WIS and found this - hope it's helpful. I'll see if there are any more useful notes too.

 

Another doc which might help too

 

Cheers Subby. I think the chain is caught up somewhere down at the crank, simply haven't got enough chain to go on both inlet & exhaust sprockets.
Probably need to drop the oil pan a bit and remove the lower timing chain cover as the head is fitted and torqued.

I'll have another go tomorrow, had to take a break as it so,so frustrating, annoying more like.

 

ah then you are probably right something is binding, usually with the chain tensioner off there should be enough slack to put the chain on.

is there a way to put the chain on the sprocket and then put the sprocket on the cam before you pull the timing chain cover?

 

No, not really. Sometimes there's enough slack to nearly allow the exhaust sprocket to go on but it's short by one link.

 

There's no doubt this problem is self inflected, basically I've screwed up (so annoyed with myself you wouldn't believe). Fairly sure the chain is binding somewhere behind the lower timing chain cover.
Since the head is torqued down, to remove the timing chain cover I'll need to drop the sump/oil pan to remove timing chain cover.

 

Timing chain cover removed and here's what I found.

I'm 99% certain the chain got caught got below this casting pin. The second photo with cover upside down shows the tell tale witness mark. Well how did this happen? Simple I reckon, as I didn't have the chain pulled up enough (a little too much slack) when fitting the cover.

Now, this can only occur when removing the cover to replace the chain guides otherwise if just replacing the chain (split link chain) and tensioner there's no need to remove the cover. The chain can be allowed to fall down (which is stopped by the centre casting bolt hole at the top of the cover) but more importantly the chain can't get caught anywhere unless the cover is actually removed.

Here's how the chain needs to be sitting when refitting the cover not matter if the head is on or off. i.e. no slack especially near the crankshaft sprocket.

On a positive note, hopefully this thread may be of use to somebody else replacing the T-chain guides.
Anyway, I'll go away now and beat myself up some more!

 

Looking good - one step closer to getting it up and running again!

 

Ha, more like one step forward and one back! Yeah, nice to find the problem and should be making progress from now on, unless I manage to screw something else up...

Kicking myself as I was sure the chain didn't have too much slack on it when I refitted the cover but it's not the end of the world, only time and I'm not under any pressure to have it up and running, the only thing I need is a new sump/oil pan gasket which I should have very soon. Thanks for your input all the same.

 

The exhaust sprocket almost walked itself on. Happy it's sorted.

As it should be.