bodhi-
listening to the aftermarket manual was definitely your first mistake (get the FSM!!!!). A search should have been done and if that didnt yield what you were looking for answer wise then start a thread. That said...
I tend to think a linkage error, like everyone else has said. I do not own a 240, but have looked at enough ones to think that is the most likely culprit. A misaligned valve would have yielded a "no start" situation or at best a "poor run" situation.
You post quite a bit, and from my deduction know enough about these things to have not made an amateur mistake, but we all have our "moments"....
Check that linkage and the rubber line to the silinoid and im sure you will kill two
at one once...
Good luck, we are here for you...
BTW, this is why pre '76 M117 engines rock, hydraulic compensators!
__________________
". . .back before accountants designed cars"
-Current Stable-
'78 MB 450SL-C 107.024.12.020783 #3840 <Kayleen>
'85 FORD F250 6.9L Diesel <Allison>
'98 Lexus ES300 <Rachel>
Long Gone...
'74 Chevy G10...........................'99 GMC Yukon 4X4
'83 Chevy Suburban 6.2 diesel .....'99 SAAB 9-5
'90 Mitsubishi Eclipse GS............. '01 Chevy Tahoe
'98 Nissan Altima .......................
'02 MB ML320
'88 Chevy Suburban V2500 4X4 6.2 diesel