1992 4.0 engine replacement with a 1999 4.0

[maconneck]

I Just recently more like yesturday replaced my ford explorer 1992 4.0 engine with a 1999 4.0
After changing the motor mounts and block brackets reusing my old intake manifold and exchanging the left exhaust with my existing one.

I rewired my harness to accomodate for the cam pos sensor and the intake manifold sensor, cannot find the engine knock sensor on this engine so it is still hanging off of my harness, a few other odd and ends.

It started up and I get a code 118 for the temp sensor and a hard code or a 998 and check engine light which I know means the computer has gone to default .
It runs ok I lack take off power the gauges look good oil pressure seems a little on the high side but steady.
Already tried to reset the ECM the codes and check engine light keep comming back.
Has anyone out there ever done this type of swap or have info that can help me fix these codes I do have my old CmPS will it work on that engine or is the wiring of the new one sufficient?
As the Beatles would say
{Won't you Please......... Please.... Help Me...Help me Help me.ee. eeee

 

[BrooklynBay]

Welcome to this forum! So you put an OBD-II system in place of an EEC-IV system, and modified the original harness. You are better off getting an entire OBD-II harness to prevent "electrical gremlins" from showing up.

 

[410Fortune]

You should have used your 92 sensors, ignoring the cam position sensor.

What is this intake manifold sensor you speak of?

Basically all you wanted from the 99 engine was the block and heads, the intakes, sensors, everything else would stay from your 92 block.

Your computer does not understand the CAM position sensor, so wiring it up was a bad idea.

What fuel rail did you use? I assume you retained the 92 fuel rail?

OBD-I code 998 = Hard Faults present = not good!

You could likely use the 92 knock sensor with the new 99 block as well.

 

[BrooklynBay]

Was the 99 engine an OHV or a SOHC?

 

[USS RIGHTEOUS]

Hey, I'm dropping a 99 engine into a 94. How have you made out so far? Maybe we can help each other out.

 

[maconneck]

Engine transfer com.....p..........l.......e...........t......?

:exporange I am glad to hear that there was a response to my post Did not know weather there was an interest in it for others so thanks people.
first off the wiring harness for the 99 was not the same and did not seem
to have the right connections the wire colors and all was not looking at all the same to even the connectors.
I used the intake manifold from my 92 explorer
I finally got rid of the hard codes it was a faulty engine temp sensor after I installed a good one the computer came on line, and the check engine light went out to stay has not been back and is not welcome.
I have been driving the truck since then and i am now working on a 411 and a 538 code that comes up on the obd scanner. i checked all the sensors and they checked out good ,I have a little stumble in the enging or should I say the rpms go up and down ever so slightly but consistently.
no problems with start up stallings or any thing that I feel to be concerned about.
So all is positive so far it worked out great and I have defeated the sceptics
1.There is a different part # fuel injector in the new engine I left that intact with the plenum as I dropped it in
2.The crank sensor on the new engine is working fine also and the camposition sensor I quess
It seems to be running fine except the few glitches I mentioned above
I am leaning more toward maybe my PCM is kicking the bucket
any Ideas?
any-one care to share with me a helpful bit of info based on my new conclusion I am listening and will take info into concideration so shoot!
Not literally

 

[maconneck]

By the way It was an over head valve engine and I cannot find a knock sensor on the new engine so what do I do with the knock sensor connection from my old engine ?
It seems to not know that it is not connected so I am up for any Ideas again.

 

[BrooklynBay]

Disconnect a block off plug, and install the knock sensor from the old engine.

 

[maconneck]

Is knock sensor necessary?

Do you think I really need the knock sensor?
Is there a way to check and see if the computer is actually calling for that information?
Last or all do you think that the KOER diagnostis test's operation is affected by this knock sensor missing out of the circuit?
BTY does anyone out there know how I can test the computer circuit or pule going to the fuel injectors, I want to know if they are all being fired correctly

 

[USS RIGHTEOUS]

I just got my engine installed. My truck is a 94. The engine is 99. I did not have a knock sensor in my 94, but there is one hanging off of the 99 engine. I assume they installed that due to the higher compression heads on the later engine. Won't know if I got to deal with that 'till I get the truck running. May have to run on higher octane, or see if I can play with the cam sensor or crank sensor and trick the computer into cranking the timing back a few degrees if it pings. I stuck with the 99 injectors also, but left the 99 lower intake on too. I measured the resistance and they were the same, so I figured what the heck. Boy it's bad enough that you have to run into bugs with a swap like this, but to have faulty sensors just makes it harder. There is a possibility that you may have a bad computer. I'll let you know how things progress as I get mine running. The fluctuating idle may also simply be a vacuum leak.

 

[ohe_boy]

Would a crate engine for a first gen have been easier to install? Doing a swap from a 92 4.0L is well worth it?

I'm also considering doing a engine swap out in my 94 and just looking around for info. I realize that electrical harnesses and computer things come into play when swapping out the engines and want to know why the 99 4.0L became your choice for a engine swap.


Thanks

 

[410Fortune]

okay when you put the 99 engine into your 92 you should have ignored the cam position sensor......1992 does not have one.

Your 92 computer does not want to see a signal from a CAM position sensor..wiring it up is a bad idea
knock sensor is not needed if your 92 did not have one, if it did then try to mount it to the 99 engine

The sensors on the 99 intake may or may not work with your 92 engine (IAC, TPS, EGR), I would be safe and re-use the 92 sensors if it was me, regardless of using the 92 metal or 99 plastic intake plenum

Bottom line when working with 4.0L OHV conversions:
make the donor look like the one you are replacing
So if you use a 2001 engine into your 93 truck, strip the 01 engine down to the lower intake...then bolt all your 93 stuff on top of it.

Big changes are:
91-92 single 02 sensor
93 no EGR no cam sensor (except CA trucks)
94 has EGR, has CAM sensor
95+ stronger heads, more compression
95+ plastic intake
96+ OBD-II
96+ 8 bolt pattern on crankshaft
98.5+ returnless style fuel system

 

[maconneck]

Ok i got the responses and Found them to be interesting.
My 1992 engine did have a cam position sensor on it and i just changed the connector end on my harness to fit the 99 engine CPS so that seemed to work out, It has been running good again except for the constant slight up and down of the idle very minute but it can be heard and it is noticable particually by me.
Why did I go with a 1999 engine the choice of my swap?
I am glad someone asked that question
I blew head gaskets on my 1992 explorer.I already found out the cost for some new heads at the chances that they were cracked , or for a little more than it would have cost me to have them checked out and resurfaced.
Figured out what it would have cost me to repair it not knowing weather or not the block had a enternal crack or not.
I did not want to strip it down and have it checked because for that I may as well do a full rebuild on the engine.
I had a leaking rear main seal for about 5 years now and i was tired of that, thought I would kill the two birds with one 14mm wrench.
I was just going to get a used engine and drop it in {you never know what you are gonna get from a junk yard , sometimes it is rightfully named the JUNK YARD and yoiu take your chances.
So I figured if I was going to take that chance I would try to change the odds.
What were my odds of getting a good running 1992 or 1993 engine from the junk yard with low milage I'll wait for the answer ................ ok
Called around to the junk yards and found that the price for a newer model used engine was about $100.00 more than the model specified for my car, all this came with a lot of negativeness from the junk yards and even the dealerships telling me how it could never work and it will not fit and so on
I did some reseach online to find out what changes have taken place from my engine to the 99 engine and it was no too clear, so one way to find out was to try it out for size and I bought one 75% of the job was the challenge A project if you will I am satified will what has been accomplished so far.
Just for your information i would have tried to do it with a2006 if i had one on hand mabe after I blow this one up.

 

[410Fortune]

Sounds like you may simply need to use the 92 throttle position sensor, IAC sensor, and EGR...or swap back to your 92 style intake with these sensors.

When you changed the plug from your 92 style cam sensor to the 99 style cam sensor did you notice any additional wires? What if anything did you do with them?

 

[USS RIGHTEOUS]

I found that the older cam sensor used 3 wires, while the 99 I have, used 2. I connected the grey/red wire to the red wire, and the blue/orange wire to the blue/orange wire, and I just left the black/white wire go. It's a redundant ground that the new style sensor doesn't need. I'm still working out the bugs with mine, but I have no codes related to the cam sensor. It would have been nice if Ford had just left well enough alone and made them interchangable. They just don't care about us weekend warriors. Ha! Ha!

 

[maconneck]

I only had two wires on my 92 explorer engine so I just re-spliced them to the 99 sensor.
Yes and I did swap over all the upper sensors with my old intake and everthing went well with that.

 

[USS RIGHTEOUS]

What injectors did you use? Mine is running lean. Haven't been able to find any vacuum leaks, so I wonder if I should have used the 94 injectors.

 

[410Fortune]

the 16# injectors should be interchangeable between 91-97 I believe, I am not sure if the 98+ with the returnless style fuel rail still uses 16# injectors or not...I would think it does.

Suonds like you connected the cam sensor properly. However you may have to connect the red wire from the 99 sensor to a red wire in the 92 harness, this is power distribution acc on +, the grey with red you hooked it to is a sensor signal return, the computer expects to see a signal from this wire from the cam sensor, I dont believe it will power up your 99 sensor

The ground for the 99 likely comes from the block, I am not 100% sure on this but if you continue to have issues you might start there. I can check with my buddy Brett about this wiring to be 100% sure, we went through this when he put a 04 SOHC engine into his 93 sport using the 93 computer.....

I dont think the grey/red gets hooked up, instead you have to tap into the red + wire in your 92 harness for the 99 sensor....

 

[USS RIGHTEOUS]

Well that's the problem, you see, there is no red wire coming off the sensor. There's just grey/red, blk/wht, and blu/or. The wires in the 94 harness are red and blu/or. I picked up a Hayne's manual this weekend and it showed the grey/wht as the signal feed wire that goes to the injectors and so forth. Same as the red wire in the 94. The blu/or wire is blu/or in the 99 and 94. There's no blk/wht wire from the 99, so I left it go. The 99 injectors are physically smaller in diameter, but have the same resistance, so I used the 99 injectors. I have a feeling that I may need a MAF sensor. I did some reading up on some other threads. Apparently it will cause a lean condition without setting a MAF code. I'll know tonight.

 

[410Fortune]

okay lets confirm:
red from sensor to grey/red truck
blue/orange from sensor to blue/orange from truck
black/white from sensor is left unconnected

Right??
You may want to hook that black/white sucker up to the ground connection.
Sorry for any confusion its hard to keep it all straight

If you are using the 94 MAS with the 94 computer you should be fine, as long as it was working before??