The HB is irrelavent to the actual timing of the engine. It is only used to set the timing on pre Jetronic 2.4 systems. The advance or retarding of the timing is strictly controlled by the ecu on the Jetronic 2.4 and on up systems.

Are you sure that you are lining the crank gear at TDC and not the HB. Use the front TB guide washer's mark. The marks on the HB do not line up with TDC when the crank is properly set to TDC.

The engine will start and idle with the cam gear being off a tooth in relation to the crank. but will not have any power.

I'm not sure that the TB is the cause of your no start.

I do grease the crankshaft before putting the HB on. That's so it's easier to remove at the next belt change. I've found that sometimes the HB is really hard to get off the crank if the TB hasn't been changed in years.

Are you sure that the crank is at proper TDC and not 180 deg. out? Using the wrong reference mark? Or the guide washers were put on opposite?

Have you confirmed that your fuel inj. relay is working properly. I had that happen to me during a repair. Car ran before working on a different system. I did the repair. I went to start it after and it wouldn't start. I initially thought that maybe the work I had done was incorrect but shouldn't have affected the relay that was now defective. Go fiqure.