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I've actually had some units with cracked (not broken all the way) guides which would flow test perfect but when the motor ran it would have the same symptoms as a plunger guide failure. They were cracked enough to let the plunger spin just a little with the thrust of the motor but would sit...

Ray70 you did everything perfect. Yes, I guarantee the plunger guide broke and let the plunger spin with causes the timing to be off. I've had this happen a couple of times. The Delivery Valve seal doesn't matter. I don't ever replace them because Ambac wants $20 for the stupid thing. I've seen...