Cam position sensor synchronizer issues

Blue 2000 TJ

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Original poster
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Mar 27, 2024
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Hello all. I'm working on our 2000 TJ 4.0 auto. Replacing the engine with a rebuilt long block, not the original engine as it had a window where there wasn't one originally. Thank you PO. Got a great deal on it so had to have it. I'm trying to get the original CPS installed but the body will not drop down to the mounting surface flush. It stops about 1/8" from surface. The motor is at TDC, crank lined up to pointer, piston is visible thru plug hole, oil pump is at 11 o'clock, reluctor locked in place with 3/32 wire. Starting at 7 o'clock position dropping shaft into motor feel it engage cam rotates as it should clockwise but stops 1/8" proud from dropping all the way down. It seems as though it's not falling all the way into oil pump but I know it's engaged into pump because reluctor won't turn when wire removed. My first thought was to smack it with a you know what but then calmer mind says that won't be good. Are there different size housings? Got to be something simple that I'm missing here. First time doing this with a Jeep but have done this many times before w/o any thing like this. Help please. Thank you in advance.
 
I know there are differences in blocks throughout the TJ model year range, and the 4.0L engine blocks from different models (YJ, XJ, WJ, etc.) also come into play, but I don't know about the specifics of all those differences. Do you know what model and year the long block's block came from? It's possible that it came from a year or model that had a different oil pump drive assembly in there. In the TJ model year range, the first iteration was a distributor in that location, and then there was one iteration that included a cam position sensor, followed by the OPDA in the 2005-6 model years. If the block you bought had another iteration in there, that might explain the problem.
 
I do know that the casting numbers are identical 53010327AB. I know it's a 2000 block by the date on the drivers rear above the pan rail. There's a set of numbers on the right side but I think those are the last numbers from the donor's VIN. Any other thoughts where to look to identify?
 
I'm not sure if what your describing is the same problem I had, but when I installed a new distributor in my 99, the helical gear on the distributor was installed incorrectly and I couldn't get the distributor to line up correctly when trying to get it seated in the block.

I had to punch out the roll pin in the gear, remove the gear and flip it over so opposite side faced up and reinstalled it on the distributor. Once I did that it slid right into place. I've seen other members on here complain of the same problem with a brand new distributor.