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pre cat deals with fuelling so will run fine, will bring a light on for post cat/cat efficiency but this can be hit and miss. some bring a light on straight away but clear it and it can take months to come back on.
forgot about this sorry. will try and find you a pic of the hole in the box but it's definitely there though.
neither pulley should move when you tighten them up unless the locking piece isn't fully up against the pulley, that would let the pulley move slightly.
horseshoe should go in easily...
to be honest i can't remember!! been a couple of years and only did two of them!!
it's easy to work out what stops the upper inlet from fitting properly.
they run fine on the correct bosch/denso plugs as well. for some reason though some places list the super 4 bosch plug for them and they don't run right with them in.
sounds like valve/piston contact? not hollow enough to be waterpump. double check cam timing etc...
or drop the aux belt and run it without for bit and see if the noise goes. sounds like a couple of different noises though??
horse shoe was miles off to say the least.
you can check map at idle (not sure on the exact figure you should see though sorry) there s a window on the bellhousing and four timing marks and a mark on the flywheel, line it up with the '0' and double check the horseshoe fits in the cams properly.
they can be funny to say the least, this one ran fine and pulled well...
did you check on the flywheel to see if that was lined up? screwdriver gives you a rough idea on tdc but the drilling must only be a degree or two out.
squeeze the end of the plug caps and see what they do, don't be surprised if they split and fall apart.
also before you take the upper inlet off check none of them are trapped under it.
start from scratch on it, check plugs and leads etc. plug caps can split up and arc out.
then quick compresssion test and chuck it back together. check resistance on the injectors. clean throttle body (fiver says it's minging)
run it and check live data from cold start, chances are lambda is...