Hi folks, I recently performed an engine swap on my standard 1996 302 standard. I put a '94 302 in it. Once I worked the kinks and found homes for connectors everything ran fine. However, recently the truck has been running Extremely rich. Scan tools read lean. I'm going to upload some pictures of a few things I can't figure out. I've been using alldata as well as chiltons and google to figure out what goes where.

I was wondering if anyone has a picture or diagram with the wire harness which plugs into the injectors and all sorts of goodies. Used the 96 harness and put it on the 94.

Addressing the lean condition. I know that vacuum leaks can cause a "lean" condition which changes the pulse width of the injectors to add more fuel to compensate. I'm thinking it has to do with this component which isn't plugged in.

There are 2 lose connectors on old harness which could go into the evap purge solenoid (I think). EDIT, It is the Canister Purge Solenoid.

Light gray connector: red and brown wires.

Black connector: Red and white with red stripe.

The component next to egr and throttle body is the evap purge solenoid? Or is that rear right near coil pack? I'm thinking this being unplugged has a lot to do with my rich condition. And does anyone suspect these 2 connectors plugs into it? They both fit, I'm wondering if these could be cut and spliced into the lose connector shown? It has wire colors green and black.

 

The pic with you holding the 2 connectors (grey & black ) are the TAB & TAD solenoid connectors. The latter connector you are right about as the Canister Purge solenoid. The others I can't make out.

I had a similar issue as are having now, but I eventually figured out that the plugs were gapped to far..really. What worked on my 92 roller cam did not work with my rebuilt .40 over 90, flat tappet cam. The rich condition only got worst with time, and I kept thinking it was the PCV, and it wasn't. But let me point out, be sure your PCV is working correctly or it can give you the same problem. If the O2 sensor is old, old, swap it with a new one and check again. What plugs and gap are you running? What I had for .56 didn't work and now I'm at .44, and timing is at *12 BTDC.

If you swap a new PCV, stick with Motorcraft, cuz a few more bucks for the right part, is worth every last cent.

 

Did you transfer the crank sensor and EGR valve and tube from your old motor to the '96? If not you need to.

What codes are you getting?

 

I was a little frustrated when I posted. The truck is a '96, and I put a '94 in it with some help from my dad and neighbors. The '94 was from a junkyard. It had mostly everything from the '94 on it. I used the '96 harness. I ran both a KOEO and KOER. The running test showed codes...
P0385 KP sensor b Fault
P0135 H02sII Heater Circuit fault
P1127 H02s downstream not tested
P1137 H02sI2 sensor indicates Lean
P1408 EGR flow out of range
P1116 Ect out of range

It also said OBDII scan not completed. Probably due to the '94 being an OBDI. I took out the EGR and inspected it. It seemed fine, no gunk.

I used the '94 coil pack because it wouldnt start hot with the '96. However I'm thinking it may have been a coincidence. I haven't checked pcv yet. I didnt check all Vacuum lines and they all seemed ok.

All parts from the '94 are on it. The EGR is from the '94, and the '96 engine is already gone.
I didn't think of the spark plugs. They are motorcraft for a '96 302, maybe the '94 is different, ill check on it.
Thanks for the suggestions

 

Ford used different EGR systems starting in 1996. You should have swapped the DPFE style EGR components from the '96 engine over to the '94, which uses a position feedback (EVP) based EGR system. That is the cause of your P1408 code.