In 05-06 Jeep switched from the PCI bus to the CAN bus. Along with that, they changed the firing rotation on the engine. PCI is every 120 degrees which puts the CPS over on the left side of the motor, right below where the head bolts onto the block. CAN is every 180 degrees so the CPS is located on the right side just above the starter area.
When you swap an AW-4 into an 05-06 TJ, there is only one current method to make the CPS function. The solution is a CPS relocation kit that moves the sensor to a bracket beside the harmonic balancer and a new balancer is installed with the notches for timing cut into it around the perimeter at the same degrees of rotation and number as they are on the flex plate rim, just miniaturized.
There are 2 problems with that. The first is the notches are not discrete enough even though the surface feet per minute is much slower through the sensor than the much larger notches on the flex plate.
The second problem is the balancer is rubber mounted to the base pulley or it wouldn't function as a harmonic balancer.
The combination of the two issues produces a flickering check engine light at anything over 3800 RPM. When the RPM drops below the threshold, the system relearns and the light quits flickering. There is no air gap adjustment that changes the threshold or how it reacts to the RPM threshold.
So, I'm going to attempt to hack a hole in the bellhousing at the proper 05-06 location, re-drill a 42RLE flex plate to adapt it to the AW-4 torque converter, and then build a bracket that picks up the two bellhousing bolts that will put the 05-06 into the proper alignment to hopefully fire the motor correctly.
What I'm looking for is anyone who is sensor smart who may know of a narrower band sensor that will read the notches in the balancer without blurring them and causing the CEL issue or anyone who has dealt with similar and knows of something I am drastically overlooking.
If the AW-4 converter is too large to fit inside the 42 flex plate rim, I can solve that with a custom converter, I'd rather not.
If a more discrete sensor exists, I'd rather do that first although I don't think it will solve the rubber mount issue.
Anyone??
When you swap an AW-4 into an 05-06 TJ, there is only one current method to make the CPS function. The solution is a CPS relocation kit that moves the sensor to a bracket beside the harmonic balancer and a new balancer is installed with the notches for timing cut into it around the perimeter at the same degrees of rotation and number as they are on the flex plate rim, just miniaturized.
There are 2 problems with that. The first is the notches are not discrete enough even though the surface feet per minute is much slower through the sensor than the much larger notches on the flex plate.
The second problem is the balancer is rubber mounted to the base pulley or it wouldn't function as a harmonic balancer.
The combination of the two issues produces a flickering check engine light at anything over 3800 RPM. When the RPM drops below the threshold, the system relearns and the light quits flickering. There is no air gap adjustment that changes the threshold or how it reacts to the RPM threshold.
So, I'm going to attempt to hack a hole in the bellhousing at the proper 05-06 location, re-drill a 42RLE flex plate to adapt it to the AW-4 torque converter, and then build a bracket that picks up the two bellhousing bolts that will put the 05-06 into the proper alignment to hopefully fire the motor correctly.
What I'm looking for is anyone who is sensor smart who may know of a narrower band sensor that will read the notches in the balancer without blurring them and causing the CEL issue or anyone who has dealt with similar and knows of something I am drastically overlooking.
If the AW-4 converter is too large to fit inside the 42 flex plate rim, I can solve that with a custom converter, I'd rather not.
If a more discrete sensor exists, I'd rather do that first although I don't think it will solve the rubber mount issue.
Anyone??
