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Old 05-24-2015, 02:32 PM
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OPDA Replacement Gone Wrong

So, I read the threads and watched the videos for the 05/06 OPDA replacement. I thought I was smart enough to do it, but apparently not. I initially had the car in gear and the brake on while turning the crankshaft by hand to line up the holes in the assembly so I could put the plastic pin in. I eventually realized my mistake and put the car in neutral, lined up the holes, then proceeded with the replacement.

There must have been some tension somewhere that caused things to move because when I put the new OPDA in the assembly was rotated about 45 degrees clockwise from where the old one was. I figured, maybe incorrectly, I could hand crank the motor with the assembly and pin in place back to a point where I could tighten things in the same place as the old one and start the car again.

When I started the car it tried to start but was super rough and never caught. I tried to slightly rotate the OPDA housing while trying to start the car and there were times it seemed to do better, but it would never go. Then it stopped trying to start and just started clicking. I tried a few more times and it tries to start, but reverts to clicking again.

Any ideas on how to fix it? Assuming it can be...

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Old 05-24-2015, 04:19 PM   #2
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Mine went pretty smoothly, but I think if you remove yours again, rotate the engine to top dead center using the timing marks on the main pulley and the block (look up from beneath to line them up), line up the holes in the OPDA assembly, and reinstall you should be good.

I'm sure you experienced this, but when you remove it from the block it has to rotate a certain amount to disengage from the drive gear. When you reinstall you have to start it back in at the same position you pulled it out, then rotate it back into place on the drive gear. That's why the videos on here show the guy using a sharpie to mark both a starting point and where it rotated to when it came free.

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Old 05-24-2015, 05:00 PM   #3
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The reason things moved is because the cam and OPDA gears are helical, and they rotate as you insert/remove the OPDA.

The reason your engine is not starting is because your OPDA (which has the Cam Position Sensor) is out of alignment that the engine is trying to protect itself. Also you may have a P0016 check engine light now.

Did you try to start the engine in with the plastic OPDA pin in place?

Here is what you need to do to fix your issue:
First find TDC:
-Disconnect negative battery terminal
-set the parking brake & put transmission in Neutral.
-Remove the serpentine belt so the zero timing gauge (see picture below) on the block is visible
-Use a 3/4in socket and a racket to turn the crank pulley in the CLOCKWISE direction(looking at it from the front of the engine).
-Turn the engine until you line up the TDC mark and the zero timing gauge (if you go past TDC you need to go around again)
Install New OPDA
-Insert new OPDA keeping in mind it will rotate ~30*, so install with it in the 2 o'clock position and it will rotate to 4 o'clock position
-Secure OPDA w/ hold down bracket and connect Cam Sensor and install OPDA cover
-Re-install serpentine bolt
-Reconnect battery

There is a lot more info on this in a thread i started here: https://www.wranglerforum.com/f210/05...l-1022825.html

Here are the TDC alignment marks:

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Old 05-24-2015, 05:05 PM   #4
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Quote:
Originally Posted by njs552 View Post
The reason things moved is because the cam and OPDA gears are helical, and they rotate as you insert/remove the OPDA. The reason your engine is not starting is because your OPDA (which has the Cam Position Sensor) is so far out of alignment that the engine is trying to protect itself. Did you try to start the engine in with the plastic OPDA pin in place? Here is what you need to do to fix your issue: First find TDC: -Disconnect negative battery terminal -set the parking brake & put transmission in Neutral. -Remove the serpentine belt so the zero timing gauge (see picture below) on the block is visible -Use a 3/4in socket and a racket to turn the crank pulley in the CLOCKWISE direction(looking at it from the front of the engine). -Turn the engine until you line up the TDC mark and the zero timing gauge (if you go past TDC you need to go around again) Install New OPDA -Insert new OPDA keeping in mind it will rotate ~30*, so install with it in the 2 o'clock position and it will rotate to 4 o'clock position -Secure OPDA w/ hold down bracket and connect Cam Sensor and install OPDA cover -Re-install serpentine bolt -Reconnect battery There is a lot more info on this in a thread i started here: https://www.wranglerforum.com/f210/05...l-1022825.html Here are the TDC alignment marks:
The only thing I'd add is that since the crankshaft pulley rotates two times for every rotation of the OPDA, you have to be sure you have the TDC marks aligned on the compression stroke, and if you go past TDC, you'll have to rotate the crankshaft pulley two full revolutions, not one as stated above.
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Old 05-24-2015, 05:28 PM   #5
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Quote:
Originally Posted by LJ Dave View Post
The only thing I'd add is that since the crankshaft pulley rotates two times for every rotation of the OPDA, you have to be sure you have the TDC marks aligned on the compression stroke, and if you go past TDC, you'll have to rotate the crankshaft pulley two full revolutions, not one as stated above.
Good point. I should have added this in my post. Although it won't hurt the engine if the OPDA is accidentally aligned on the exhaust stroke. It probably won't run well, and then OP will know he is 180* off.

If possible it would be good to pull the #1 spark plug while finding TDC to make sure to align everything on the compression stroke.
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