2006 Jeep Commander 3.7L Engine P0016 Code: Cam-Crank Timing Issue After Rebuild with OEM Parts
I'm experiencing a persistent P0016 cam-crank correlation fault on my 2006 Jeep Commander 3.7L engine. I recently completed a full engine rebuild, including new remanufactured block and heads, all new sensors, timing guides, tensioners, chain set, and cam gear with reluctor wheel. I've meticulously verified the timing marks multiple times—both visually and using the factory TDC alignment method. After taking it to a dealership for diagnostics, they reported that the engine is 5 degrees out of time. However, upon disassembling the engine again, I confirmed that the cam and crankshaft are perfectly aligned at TDC: Crank gear at 6 o'clock, idler at 12 o'clock, both V-6 cams at 12 o'clock with proper balance line alignment. I've replaced all three camshaft and crankshaft position sensors (all MOPAR OEM parts) multiple times. All wiring and connectors are intact, voltage readings are within specifications, and sensor signals appear normal during operation. My question is: Could the remaining timing gears—despite appearing undamaged or worn—still be causing a 5-degree misalignment due to unknown mileage or manufacturing tolerances? Additionally, could a faulty Powertrain Control Module (PCM) be generating this code intermittently, especially since it only appears after the engine reaches operating temperature? The vehicle starts smoothly with no hesitation. The P0016 code appears consistently at operating temperature and clears when the engine cools down. Periodically, I also see a #2 injector fault code that disappears shortly after—though this may be related to the timing issue. I'm seeking insight into whether sensor signal noise, PCM malfunction, or mechanical tolerance issues could explain this behavior in a properly timed 3.7L engine.
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