Engine Knocking, Rough Idle, Misfire? Video

[keepthecoffeeon]

Alrighty a little background.

I recently put the following new parts on my 1999 4.0 OHV Explorer

130 Amp Alternator
Upper Intake Manifold
Fuel Injectors
Fuel Rail Gasket
Replaced the EGR Tube O-Ring


The first time I put everything back together my truck ran with no knocking at all. The issue was one of the O-rings on a fuel injector did not seat correctly into the fuel rail and subsequently was leaking fuel so I had to take everything off to fix it.

Second time around I got everything seated correctly, all hoses and connections, etc. And now I have a terrible knocking noise in the engine and I for the life of me cannot figure out what is wrong.

I've tripled checked my firing order for the spark plugs from the cylinders to the coil pack.

I've noticed when I disconnect the vacuum hose from the EGR valve the vehicle runs smoother for about 5-10 seconds, the knocking subsides somewhat, when I reconnect it knocks more rapidly.

Fluids are all normal.

The EGR tube gets extremely hot even if the car is only on for 30-45 seconds... I posted a video of the sound to maybe give you guys a better idea.

I'm also not sure if its because the alternator is new but it smells awful

 

[keepthecoffeeon]

Any ideas fellas? Still haven't been able to figure anything out. I'm taking her apart Thursday to see if I can find anything.