I have a 2002 f150 5.4, I just finished swapping the engine with a rebuilt 5.4 from a 2001 expedition, I have replaced the fuel filter, ignition coils, starter, battery, iac valve, pcv valve, intake manifold, I found a after market air intake at a junk yard with a spectre air filter, numerous other parts. I just replaced a couple ignition coil clips that had broken tabs that were preventing the clip from seating properly onto the ignition coil. Before I had replaced the clips when i would try and start it, it would be very hesitant but eventually start with some gas, it would start up roughly and after a few minutes of letting it idle there was a strange on and off whisping sound I could hear from around the throttle/intake manifold or EGR areas. I have smoke tested multiple times and at first there's nothing but after a few minutes of running air into the engine (after running smoke for a while) I noticed a tiny bit of smoke coming from the EGR but not coming from the EGR gasket. After replacing the ignition clip that I had a code for it was idling a lot better, after replacing the clip I realized the one next to it I had broken the tab on also had electrical tape on it and was very easy to take off so I decide to replace that clip also. After replacing it I found a code for idle air circuit, I was very confused because I have a brand new iac valve which is a iac valve from a 4.6 l f150 because every brand new one I bought would leak air out of the pressure cap on the side so I decided to get one without that cap. I reset the PCM by disconnecting the battery and after that the code had disappeared. After I was not able to start the engine, it would start with a little gas and die immediately.

 

Welcome to the forum. Lets see the truck.

 

Thank you! I apologize this is the only picture I have because my phone is getting fixed and I am using a back up phone right now, I can take better pictures in the morning, this is a picture from when I was smoke testing for vacuum leaks

 

Have you checked the fuel pressure & regulator ?

 

I would also suggest checking fuel pressure and make sure crankshaft position sensor is plugged in good. When you get it up and running I would suggest putting a stock air intake on it.

 

I did check the fuel pressure and it seemed right according to some research I did. but I have not checked the fuel regulator yet

 

 

Does anyone know where the other end of this ground wire connects to, I suspect it connects to the back of the block or cylinder head but I'm not sure?

 

today i replaced an ignition coil clip on cylinder 1 which was the last thing i replaced before it started not working and i also replaced the crankshaft clip on the the harness, its cranking nicely but not starting and i have no trouble codes.

 

See if a little starting fluid will cause it to fire up.