Your thread is somehow locked so I can't reply there.
http://www.zukiworld.com/forum/technical-discussion-beginner-repair/96-1-6-16-valve-cam-timing/ I am putting a Head on a 1.6 16 valve engine in a 1996 Sidekick 2door 4x4 and it was already taking apart. My problem is the cam sprocket has two different slots that it can be installed on the cam. I need to know which one to index to the cam. The other problem is I went by All Data Instructions to time the engine and when I turned the engine over I had no compression, obviously I screwed up. I brought the piston that is closest to the front of the engine which I thought was # 1 up to TDC with the v mark on the crank pulley and aligned the cam sprocket with the mark that it called for in the Instructions, adjusted all the valves as it said. That's when I tried to start the engine and it had zero compression, If someone could walk me through a couple of these steps that I am not getting I would appreciate it .
2 things: You may have an older cam cog or engine, as far as I'm aware by '96 they stopped using the dual keyed cog. But to answer that question you should use the 'E' marked keyway.
Also the 1.6l is cam timed to TDC #4
not #1. Ie, when the crank mark is up & the cam mark is up, you are at TDC #4. You are correct the front piston is #1 with 1 2 3 4 in order front to rear. Be aware the dizzy on a 16v rotates counterclockwise with firing order 1-3-4-2.
So, you have the cam 180* out. Also be aware that the FSM warns it's an interference engine!!. I know other posters might insist it's not, but I'll stick with the FSM & several people who've destroyed 16v's.
Check out Kick-fix.com, he has good clear instructions for setting the cam & ignition timing.
http://www.kick-fix.com/t-belt/16-fast-belt-install.htmlHth,
Fuzz
