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No Start on 1.6L engine rebuild - cam timing?
I have a '94 1.6L (4AFE?) with 144k miles. A while back, it wouldn't start one morning. After checking everything else, I found I had low compression on all 4 cylinders. I pulled the engine, stripped it to bare block and took the block and head into the machine shop. The shop said the head failed a pressure test because the exhaust valves were carboned up and not closing fully. I had them do a valve job (which is horrendously expensive, BTW!) and put it back together. I can't get it to start. I was very careful putting everything back together and torqued everything down properly. I'm showing about 95 lbs. compression on all 4 cylinders. I'm guessing it is my valve timing, since the Haynes manual I used on the rebuild had terrible instructions on setting it. I've searched and can't find anything definitive. I set the notch in the timing pulley in line with the mark in the cap behind it with #1 at TDC. At first, I then set a dot on the intake cam gear to match up to the dot on the exhaust cam gear (while #1 still at TDC). This didn't work. I then noticed each cam gear has several of these dots. I read somewhere that the dots you're supposed to use are on the back of the gears. Sure enough, there is a dot on the back of each gear, which is a tooth off of the ones on the front. Setting it like that didn't do any good, either, though. What is the right way to do this?
Any help would be greatly appreciated.
Thanks,
Eric
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