Actually Kyoryu Navy made his debut in Kyoryuger's Movie, Not V-Cinema.

I think ToQger's V-Cinema might be alternate timeline where Z was ToQger and he was not Emperor of Darkness

Deathryuger had red arms and was called Deathryuger. Kyoryu Navy had blue arms and was called Kyoryu Navy. Technically a reused suit but still technically different.

Zed was never truly evil, in fact throughout the entire show he couldn't care less about fulfilling the Shadow Line's goals it was always forced on him. Given where he currently is in the series, it's not hard to believe that he would reform and become good. Why are you so convinced that it' can't happen in the main timeline?

Because that's my first theory of him becoming ToQger because he is the leader of bad guys and we know that all leader will killed at final episode but my second theory is that what if Z was Right's father because remember in first episode that Right was climbing a tree and he got fall out of tree and Z could save him but Z was a divorced father because we didn't see him in a flashback.