I have a 1997 Ranger 4.0, pulled the engine apart for a rebuild. I put in a new camshaft synchronizer, using the instructions from the Haynes manual (#1 TDC, 60 degrees off center). The sensor will not fit at 60 degrees and clear the lower intake manifold, although it will fit at about 50 degrees. I was looking at the photos of the engine during the tear down, the sensor was lined up almost straight in line with the center line, and the engine was running well (rebuild for new pistons and hone cylinder walls). I am not sure what to do next - leave the sensor where it is or move it to where it was before the rebuild? Which is correct? I determined TDC by marking the harmonic balancer when the #1 piston is at its highest position in the cylinder. Photo of sensor as it was before I removed it.
Any help would be appreciated, this has me stumped.
Thanks

Sensor is positioned straight in line with center line.

 

You also need the correct TDC, there are two
Turn crank clockwise and watch #1 intake valve
It will open and then close
continue to turn to TDC 0deg, and thats the TDC you want

That's #1 TDC compression stroke
If you rotate crank one more turn to TDC 0deg that would be TDC exhaust stroke, but #5's compression stroke, 1 and 5 are matched pairs to balance engine

Now you can drop the synchro in so the wire connector is pointed where ever you want
You just need sensor needle in the middle
There is no "right position" because synchro can be pulled up and rotor turned then dropped down with rotor in any position you want as long as you are on #1 TDC compression stroke

Good article here: https://www.therangerstation.com/tec...hronizer.shtml


Cam sensor timing is the same as distributor timing, #1 spark plug wire can be anywhere on the cap as long as the distributor shaft was put in so rotor was pointed at that position on the cap when engine was at #1 TDC compression stroke

 

I will remove the valve cover and watch for the #1 intake valve to close. I am not sure what you mean with "continue to turn to TDC 0 deg". After the intake valve closes, how do I know where to turn to TDC 0 deg?

Thanks for your help! I am new at this, if you can't already tell!

 

You can just pull out #1 spark plug and put in a compression gauge OR your finger, turn the crank clockwise until you start to get pressure building up inside #1(this is the compression stroke), and keep turning crank until pointer on front of engine lines up with 0deg Mark on crank pulley

 

I do not have a 0 deg mark on the crank pulley. I replaced the crank pulley, the old one has an orange dot on it, but no other marks.
Is there a way to find this 0 deg by looking at the valves?

 

You don't have this pointer on your 4.0l OHV engine: https://www.therangerstation.com/tec...-synchro-4.JPG

 

I have the pointer on the new crankshaft position sensor, but I do not have the "0" on the pulley. The "0" is top dead center, correct?

 

Yes there should be a line on the balancer/pulley that when lined up with the pointer would denote #1 and #5 pistons being at TDC(top dead center)

In the above picture look at the tone ring, the ridges behind the pulley, you will see a missing ridge on the right of picture
You can use that missing ridge in picture to get TDC
The pointer is attached to Crank sensor
The Right Edge of crank sensor is on 5th ridge over from "the gap"
Rotate your crank to duplicate that and put a mark on the balancer where pointed is, and thats TDC 0deg

But you don't know which TDC it is yet, #1 compression stroke or #5 compression stroke
Then if valve cover is off you can rotate crank clock wise and watch intake valve, it will open and then close, once it closes you are at #1 BDC(bottom dead center)
Keep turning crank clockwise(180deg) until your mark is at the pointer, thats #1 TDC Compression stroke