4.0 swap issue

[chrwilkins30]

94 explorer 4.0 into a 88b2. Complete explorer wiring installed onto explorer. Cat is getting cherry red. Gas is getting into the oil. Has magnaflow cat due to space issues. Original can got cheery red aswell. Explorer fuel lines installed all the way to the tank. Fuel pressure at the rail is 35 psi while running. Ran perfectly fine before pulled. What to look for? Need this swap done ASAP!! Been with out a truck for 6months. Any ideas.??

 

[adsm08]

Well, it sounds like you have an over-fueling issue that is lighting your cats up and slagging them.

Leaking injector is probably the culprit.

 

[shane96ranger]

Original cat, as in the cat on the B2? Or the Explorer?


Posting whilst sitting upon the throne.

 

[chrwilkins30]

It had the original explorer cat when I put the engine in. I put a smaller cat in its place because it ran to close for comfort on the skyjacker transmission crossmember.

I didnt see and fuel leaking from any of the injectors.

 

[Andy D]

Maybe apples and Oranges, I had the exact symptoms with a Jeep 360 V8 . Trouble ended up being a weak coil. Engine would run sorta OK , Cat got so hot you could see through it. Melted the ceramic honeycomb of the cat. Split 2 mufflers. Chased the over fuel trouble with a new carb , KA-CHING. My BIL looks at it and says " got another coil? " I grabbed the coil from the parts jeep. and voila. I dont even know what passes for an ignition in the Ranger. But, I bet it isnt too mysterious. A leaky injector could be located if only one plug was dripping wet. If all the plugs are wet, it could be a weak spark.It is not the first thing you check in the situation, but it does happen. Also , seeing as this is an engine swap, it could be a simple low voltage situation. Is the engine block properly grounded?. Is the electrical system charging? Good luck

 

[shane96ranger]

It could be a coil issue. What about the O2 sensor? Is it new?

Posting whilst sitting upon the throne.

 

[RonD]

Check the FPR's(fuel pressure regulators) vacuum line, see if it smells like gas or has gas in it.
If the FPR's diaphragm leaks it sucks raw fuel into the intake, causing the run rich condition.

Motorcraft spark plugs are a must on the 4.0l, it eats other brands.

The MAF sensor plays a big role in the fuel/air mix on the 4.0l and most Fords that use MAF sensors
Good read here about the MAF:
http://www.therangerstation.com/tech_library/CleanMAF.html

 

[chrwilkins30]

Pretty sure I figured it out. There was I vacuum leak at the evap purge valvethat went to the charcoal canister. Ive ran it for 20 mins now after I replaced the valve and no red cat. It would usually do it within 5 mins. Also found an upper intalke manifold gasket leaking causing low vacuum and poor idle.

 

[RonD]

Good job

What about the fuel in the oil?
Vacuum leak is usually a Lean mix creator.

 

[AllanD]

1994 4.0 is a SEFI engine meaning thare are six distinct injector pulses.

People go batshit crazy about SEFI but it makes no difference to power and is infact a reliability issue.

and a major bite in the ass for mileage.

The reason for this is the SEFI 4.0's are also EGR 4.0's

Not that EGR itself is a problem, infact it's a damned good idea,
but the implementation used for EGR and the system installed to
verify that EGR is simply not reliable.

THAT leads to another problem, the fact that the engine management
is programmed to go basically "psycho" when it detects an EGR system failure
(or tampering with the system)

What's worse is the DPFE sensor that monitors the EGR system is the only
engine management device that I can think of offhand that is markedly LESS
reliable than the old TFI ignition modules on the 1985-88 2.3 engines.

it is also possible that through your wiring you have multiple injectors crossfiring.

IT would help to know how you wired in the 4.0 engine...

 

[UrbanRedneckKid]

People go batshit crazy about SEFI but it makes no difference to power and is infact a reliability issue.

Allan I'm sure you remember when I switched my from SEFI... I'm way happier with the batch-fire system in the long run. I think it has better throttle response, and seems to fuel better during WOT assaults.

 

[chrwilkins30]

Its still glowing now. For the wiring all I did was swap the entire explorer wiring into the bronco. No splicing done in the engine bay.

There might be a possibility with something with the egr. I did take it off to replace the pipe for it.


Only have 4 more connectors in the inside. 2 from the gauge cluster, the rear wiper switch, and hvac control.

Anyone have any wiring schematics that actually show anything for the gauge cluster that would help.