Alright, I headed out, and did a diagnosis on the engine's ignition system, here are the results:
1. Pulled the plugs, and visually inspected them:
Piston 1 = Clean, but gas fouled
Piston 8 = Dry soot, with clean threads
Piston 4 = Dry soot, with clean threads
Piston 3 = Dry soot, with gas soaked threads. Found this plug loose, was able to back it out by hand
Piston 6 = Dry soot, with clean threads
Piston 5 = Dry soot, gas soaked threads, and ceramic. Found this plug was totally loose, only took about 2 turns to back it out.
Piston 2 = Clean, but gas fouled
All plugs are AC Delco, and are the correct lenth, and heat for my heads. All were, and still are gapped at .045
2. Did a dry compression test on the engine. All plugs removed, compression tester installed in cylinder to be tested. I allowed the starter to turn so each cylinder had 6 compression strokes, just counted when the starter worked hard to turn the engine over.
Piston 1 = 140 PSI
Piston 8 = 148 PSI
Piston 4 = 140 PSI
Piston 3 = 140 PSI
Piston 6 = 140 PSI
Piston 5 = 140 PSI
Piston 7 = 150 PSI
Piston 2 = 140 PSI
3. Checked the continuity, and resistance of all the plug wires, along with a visual inspection for cuts, burns or other damage.
Piston 1 = 12.93K Ohms
Piston 8 = 7.10K Ohms
Piston 4 = 9.85K Ohms - Found a burn on the plug side boot, possible loss of spark under load to the header
Piston 3 = 10.63K Ohms
Piston 6 = 7.21K Ohms
Piston 5 = 9.63K Ohms
Piston 7 = 7.95K Ohms
Piston 2 = 14.38K Ohms - Found a cut in the plug side boot, possible loss of spark under load to the header
4. Removed dizzy, and driver's side valve cover. Turned the crank by hand until I felt air being pushed out of the plug hole, and saw that both valves were shut. Brought the timing tab up to 0 degrees, right where a guy can feel that the piston is at TDC with a screwdriver. Timing tab is accurate, immedately after passing the 0 degree mark, the piston begins to go back down into the bore. Re-set the tab to 0 again, re-installed driver's side valve cover, and set the dizzy back in, re-installing the cap, and re-connected all the electrical, less the plug wires.
5. Re-routed all plug wires to avoid running any of them within 3 inches of any sensor wiring. Several plug wires ran parallel to the sensory harness, one actually resting on the looming.
6. Removed, cleaned, and re-installed all grounds in the truck. This includes the grounding terminal block on the emergency brake assembly, the emergency brake assembly to cab connection, cab to engine connection, engine to frame connection, and battery to engine connection.
7. Tried running the truck, with no noticeable improvement. If I turn the dizzy so the truck will somewhat attempt to idle on its own, and check the timing, I have to turn the advance dial on my timing light to approx 50 degrees before the timing tab appears to return to 0.
The compression numbers seem remotely low, but this engine averaged about 125 - 130 before I removed the engine, replaced all the gaskets and installed the TPI. It ran like a top before that with the 125 - 130 compression, very smooth, plenty of power. The engine broke in on the old q-jet, and typical HEI somewhat properly. The engine did backfire out of the passenger's side header, as it primarily does now during break-in, but I had chalked that one up to two dead cylinders on the pass side due to a rather large crack in the dizzy cap (you could see it arching out and down to the dizzy base when the engine was idling)
The Check engine light acts as it should on when you have the truck in the on position, off once you get it to run, until a flag is set. If you jumper the ALDL, the ECM displays the aldl jumpered code, then the MAF high code, then the rich code.
The ECM is adjusting the timing, I got it so if I ran to the front of the truck fast enough, I could catch it before it died, and keep it going with my hand on the throttle body. When I increase the throttle, the timing mark dissapears, so I do believe the that it is attempting to set the timing.
The ECM tells me that it is running about 12 degrees at an "idle" bumping up to nearly 36 degrees when I attempt to rev it.