You said weak spark at "the" plug wire. How many did you check his way?
If you got a hot spark going into the cap, you should have a hot one coming out. Pop the cap and find out where it went. In the meantime put a shot of oil in every cylinder and let it sit for a couple of hours, overnight is better. You may have just washed all the oil off the rings by now.
Also, the new module might have affected the engine timing. She will likely start better with some extra timing thrown at her. You can back it down to "normal" after she's all warmed up.
Good luck.
Oh yeah; you said you removed and replaced the engine without pulling the D. Did you pull the engine with the trans attached? This is a tricky thing to do and not bend/break the D. You might want to pop the cap and make sure the advance system is still operative and that the center shaft is spinning nice and true. Also check the rotor is the same as the one that came out. Sometimes the firing tips are shorter/longer. Look for damage inside the cap to the tower contacts.
One more; you said you replaced the cap, and checked the firing order. What yo did not say is that you replaced the wires one by one or sync'd the #1 plug wire to the Correct tower with the rotor under it, with #1 cylinder at TDC compression. . Just cuz the cap has #1 on it does not guarantee that the rotor is gonna be there when it's supposed to be.
