Hi guys long time lurker first time poster,

I have a 02 excursion 7.3L with 190k on the clock that has had a K&N intake, Banks full exhaust, superchips on Race mode (26psi) all its life. I've always maintained it very well and have had no issues with the truck at all, I'm a mechanic and do all my work myself but mainly specialize in import turbo performance.

I recently developed a rusted out oil pan leak that got very bad, so I decided to pull the engine and change the pan. While I did this I also decided to do a couple more fairly easy mods to boost the performance of the truck. Adrenaline HPOP, new glow plugs, new valve cover gaskets/harness, van turbo exhaust housing w/o wg, turbo pedestal delete, new EBP sensor and tube, spearco intercooler, map sensor fouler, intake heated delete and all the associated couplers/clamps/ gaskets/o-rings/seals ex.... I also did a boost leak pressure test and it held 40psi after the install. Got everything up and running and have been driving the truck for about 2 weeks, initially I babied it to make sure everything was working properly, but felt like something was not right, so I bleed the HPOP oil rails per the instructions like 4 times the second day, truck ran much smoother and starts faster then it ever did.
Here are the issues i'm having, truck used to boost 26psi peak w/wastegate, now I can only get 28psi peak with no wastegate. Truck used to spool and come on boost much faster and peak the boost and hold it, now it spools slower and rises slower. It feels like there is a miss to the engine under steady throttle/cruising and as the truck gets driven further the idle at a red light gets worse and worse to the point were its shaking your filling out. The worst part is as your cruising/stopped/accel the truck will shut off at random points during the trip, ( I know your thinking CPS sensor) and that's what i thought, but i've had that problem back in 04 and the truck would throw a code and fire back up right away. This situation no code and it sometimes won't start back up for 5 min ( really annoying when your a red light with 35 cars behind you honking). So I changed the CPS and ohmd/checked out the wiring to ecu per the service manual still same thing. I've also swapped out the spearco intercooler back to the stock one thinking its the core but still same thing. I've also checked my work like 6 times. There is only one code stored in the system p0541 for the intake heater that's it. Overall the truck is slower and less responsive then before, about the only positive thing is it starts better than it ever did before.

Sorry about the long post I am just looking for some ideas to help me get this truck back up to par.

Any help would be much appreciated.

Paul

 

It feels like there is a miss to the engine under steady throttle/cruising and as the truck gets driven further the idle at a red light gets worse and worse to the point were its shaking your filling out. The worst part is as your cruising/stopped/accel the truck will shut off at random points during the trip, ( I know your thinking CPS sensor) and that's what i thought, but i've had that problem back in 04 and the truck would throw a code and fire back up right away. This situation no code and it sometimes won't start back up for 5 min ( really annoying when your a red light with 35 cars behind you honking). So I changed the CPS and ohmd/checked out the wiring to ecu per the service manual still same thing

I am having EXACTLY the same problem!!! I changed my CPS and it didn't do jack. On Friday I'm going to clean/service the IPR, pull the vavle covers and see if the harness connections are tight, clean the EBPV sensor and tube and maybe replace the ICP. Other then that I don't know what else to do. My truck was at the mechanics for 2 weeks and he said that he couldn't get it to throw any codes. Don't know what is going on with my truck...aaarrrgh!!!

 

My initial impression is a stuck or sticky IPR.

 

Where are you located at? Do you or anyone near you have an Autoenginuity (AE) that could hook up to your truck to see what your truck's internals are doing

 

Thanks for the replies! I have a snap-on scanner, the IPR was cleaned when I did the HPOP and I was very careful not to get it dirty. (do these go bad often)?

Thanks guys anything to get this thing going, I got out accelerated by a Hyundai Santa Fe this morning on the on-ramp , it used to keep up with 5.0 mustangs

 

Can you monitor live data with your scanner? When the engine starts to idle rough, you're not getting a CEL? Have you tried removing the map sensor fooler or at least unplugging the map sensor to see if that fixes or changes the rough idle? Also try unplugging the ICP sensor during the rough idle to see if it helps.

The vans don't have an intercooler. I believe the van housing is meant to help keep EGT's in check so it's going to have slower spool up than the stock housing. If you want more power, there are better options than the superchip, but we can get into that after you get back up and running right.

 

A van turbo will be a bit slower to spool but shaking or rough idle maybe a harness issue.

 

Yes I can monitor live data. What should I be looking for??

I removed the fouler today it made no difference at all except for a over boost code when I went above 25 psi for a second. I have not unplugged the map or ICP but will give it a shot over the weekend.

Thanks

 

Drive it to get it idling rough again and monitor ICP pressure in psi, IPR duty %, MAP in psi, and take a look at the perdel readings.

Peter's IPR guess is a good one. Cleaning them doesn't always work.