[Brian86992]

My 02 TJ's 4.0 died so instead of rebuilding an engine with 120k miles on it I bought a used engine. Long story short I bought the 4.0 out of a 2006 and had it shipped from California.



I just got a call from the mechanic saying that they're going to have trouble putting the 06 engine in my 02 TJ he said the camshaft and crankshaft sensors are different and in order to make the engine run they would have to swap in the PCM and wiring harness from an 06.

I thought I did my research how did I not see this before? Any help would be greatly appreciated I feel like I'm in a hole a couple thousand deep right now.

[rda616]

You will also need the gages out of that 06. The 03-06 use a different bus then the 97-02.

[JBTJ]

Sell the motor you just bought and rebuild the old motor.

[Brian86992]

Originally Posted by rda616

You will also need the gages out of that 06. The 03-06 use a different bus then the 97-02.

If possible, I'm trying to keep my old wiring harness. While it is possible to obtain the harness I'm looking at two to three times the labor cost to swap it in. I was hoping there is a workaround such as adapting my sensors to the new block or splicing the new sensors into the old wiring harness.

Originally Posted by JBTJ

Sell the motor you just bought and rebuild the old motor.

Rebuild cost is twice that of swapping in a used engine.

[rda616]

I have never compared the two blocks, but it seems to me the cheapest option would be to swap in a older style cam and reuse the old camshaft position sensor.

The splicing won't fly though, I'm certain of that.

[mrblaine]

Originally Posted by Brian86992

My 02 TJ's 4.0 died so instead of rebuilding an engine with 120k miles on it I bought a used engine. Long story short I bought the 4.0 out of a 2006 and had it shipped from California.



I just got a call from the mechanic saying that they're going to have trouble putting the 06 engine in my 02 TJ he said the camshaft and crankshaft sensors are different and in order to make the engine run they would have to swap in the PCM and wiring harness from an 06.

I thought I did my research how did I not see this before? Any help would be greatly appreciated I feel like I'm in a hole a couple thousand deep right now.

How many OPDA issues have you heard of for the 02 year model?

[Brian86992]

Originally Posted by mrblaine

How many OPDA issues have you heard of for the 02 year model?

The new engine was within my price and nearly brand new. I decided a engine with 3800 miles and a $100 part was a better deal than an engine with 100,000 miles for the same price

Blaine, do you have any insight to the easiest way to get this thing in my 02?

[mrblaine]

Originally Posted by Brian86992

The new engine was within my price and nearly brand new. I decided a engine with 3800 miles and a $100 part was a better deal than an engine with 100,000 miles for the same price

Blaine, do you have any insight to the easiest way to get this thing in my 02?

I would avoid anything that has to do with converting the rig to be compatible with the 06 engine.

I would put the two side by side and see if it is possible to swap over the engine parts from the 02 onto the 06 and make the 06 engine into an 02 if that's even possible.

At least back to 05 they changed a whole lot of stuff on the electronic side. The CPS is even on the other side and the crank pick-up is entirely different on the flywheel/flexplate so I don't even know if you can index it correctly on the new engine. I suspect you can, but you will need to verify.

It's such an issue that on Ricky's for the AW-4 swap he installed the conversion kit from AA to use the harmonic balancer for the CPS so we aren't even driving the CPS from the flex plate.

I also don't think there is an easy way to convert your 02 to be compatible with the 06 harness. Everything would have to come out and a new harness go in. There is a thread on here from a few days ago where a simple tub swap using an 05 with part of the 05 harness didn't work so well with the original 04.

Sometimes a good deal is more costly than it seems at first.

[Brian86992]

Originally Posted by mrblaine

Sometimes a good deal is more costly than it seems at first.

That's what I'm quickly realizing. I suppose there was a reason there were very little threads with people swapping in 05-06 engines

[mrblaine]

Originally Posted by Brian86992

That's what I'm quickly realizing. I suppose there was a reason there were very little threads with people swapping in 05-06 engines

I'm not saying it can't be done, I just don't know how to do it or even the best place to start.

I realize the appeal and I wish I knew more.

[svtkev]

i work at a salvage yard and according to our interchange the block and head shows to be the same,i would think if you stripped it to a long block and transfered everything over from the 02 it should work

head interchange:
cherokee '00-01
grand cherokee 99-04
wrangler 00-06

block interchange:
grand cherokee 99-04
wrangler 00-06

[Brian86992]

That's a small beam of light. I plan on stopping by the shop after class to assess the situation myself. If that were the case I would be a very happy camper.

[Brian86992]

Well things looks good. It seems the mechanic saw the OPDA and immediately thought it couldn't be done. However, after looking into things deeper their reman engine supplier's numbers (Jasper) also confirm that 2000-2006 blocks should be identical. That said, I was able to drop by the shop and snap some pictures.


Old coming out


Old next to new


The 2006 is very clean


02's ODPA/CPA

06's OPDA/CPA


Those are the parts that were in question earlier today.

Now, Blaine, here's the zinger. Right after I left the shop I got a call reporting that my 2002's OPDA's gear was abnormally worn, nearly no teeth were left. I didn't see it myself but it sounds like I did in fact have a rogue non 05-06 OPDA problem.

[svtkev]

good to hear and that motor does look really clean

[Brian86992]

Originally Posted by svtkev

good to hear and that motor does look really clean

Thanks for posting up the block compatibility. I'll update this when more progress putting in the new engine is made.