95 4.0 with EGR converted to 91 4.0 wiring harness with no egr LOTS of photos

[BabyBronco89]

so spent the night changeing all the components on my 95 explorer 4.0 with EGR to match up with my 91 Non EGR wiring harness

let the fun begin

okay heres the 91 4.0 with no egr in my B2

heres the 95 4.0 with EGR

and again

i do like the 4.0 EFI image on the plastic intake too bad its only for the EGR

Nice shiney new alternator

okay heres the majority of all the EGR bs on the drivers side manifold and intake

and again

heres the blown 91 4.0 sitting on top of my funked up stock 2.9
the two plugs below the alternator are the only ones that plug into my harness which i like nice n simple

close up passenger side 91 4.0

95 4.0 intake manifold with all the EGR bs attached n wiring

the engine wiring harness for the 95 4.0 egr with the intake and most egr components its huge and excessive

the 95 4.0 stripped of the intake manifold and wiring harness, also removed the compressor less weight less trouble

removing the exhaust recirculation line to the manifold need to find a plug the right size n thread

also i just broke off the part that attached to the intake manifold

Heres my temporary fix till i get a plug the right size, not a bad picture either makes that rusty broken egr pipe look good, love my iphone 4s

Its ready for the 91 4.0 wiring harness and the 91 intake manifold

Here's the 91 4.0 wiring harness orientated sort of where it would layon the egine , you can see the 6 fuel injector plugs in line in the middle and the two plugs that connect to main harness

heres the 91 wiring harness in place on the 95 engine NO EGR anymore

here it is about ready to go in
just a few more finishing touches

give me some feedback
also have some questions regarding running a newer sohc 4.0 on a 91-92 wiring harness can it be done?

 

[adsm08]

Did you look over the intake well to make sure there wasn't any debris in it?

Snoranger is the one to talk to about running a SOHC engine on an OHV harness. He has done it before in his 95.

 

[BabyBronco89]

yeah after taking the intake off the 91 i found there was nothing but water in the intake chamber closet to the trans im guessing i blew a head gasket or cracked a head and coolant was drawn into the cylinder head, which is what snapped the rod
th intake on the 91 wsaas actually very clean, they said it had been rebuilt 10,000 miles ago but after sitting for a yr or more head gaskets will rot n deteriorate
the 95 intake manifold is what really worrys me there is lots of black carbon deposits and grit n grime
thinking about getting a 2nd hand one from the JY n cleaning it up n swap mine out at a later date

and thanks i will defintaley be looking into the SOHC 4.0 n see what info snoranger can pass on.

 

[ronclark]

I used that plastic intake on my 4.0L i put a rubber expanding plug in it

 

[BabyBronco89]

Looks good I think I'm going to end up painting the aluminum one black and etching a custom 4.0 badge in it