I think the part I highlighted above indicates a PCM reset. If I remember right thats commonly the main harness under the dash isn't it fellas?

 

Id be doing the "scientific" wiggle test under the hood. Start the engine,, then start wiggling wires. Pay specific attention to all the 3+ wire sensors,, and at the big parts of the loom. Then, unplug and plug in the sensors one at a time. Generally the cam or crank sensors work, or they don't. But it very well could be wiring to one of the two sensors.

 

ICP volt with KOEO should be .22-.25V.
Has ICP harness and sensor been inspected? Is it covered in oil? Has ICP sensor ever been changed?

 

I picked it back up from the dealer today, darn thing stalled out 12 times over 10 miles home.

I was wondering about the ICP -volts being low, I've never changed or serviced that sensor but thinking I will change it out. I'm wondering if that sensor is bad how much of my other data is inferred and not actual.

It idles high, 900-1000 rpm, Ford asked about thermostats and the truck not sensing its warmed up? yet sometimes it idles really low to like 500 to 600 rpm. I'm wondering if the idling differences are related to the wiring and injection issues.

I'm looking up parts right now to replace the harnesses's. I see the main harness is part#12B637, but there's a difference before or after Sept/2003. The serial number on the rear of the engine is no longer visible, nor is the one that's supposed to be on the FICM with build date.

Can anyone remind me of the difference in the engines at the Sept.2003 build date to help me identify which part I need?

While I'm in there I'm going to put in the bullet proof EGR I ordered last year and haven't gotten too. Any other recommendations on important mod's from stock while I'm in there?

 

Before investing $700 on a new harness, check the PCM ground and power wire. The coil light in the dash says your loosing power to the PCM, you could have a loose ground.

Or it could be a bad PCM.

It should idle at 650rpm. ICP should be 580-650 and voltage at .8 when idling. .18-.24 koeo

 

Sorry for the dumb questions....I think I narrowed it down, early 03 build because the ICP sensor is down low not up on the valve cover.

 

ICP is near the turbo on the 03'

 

unplug the the icp sensor. it is under the turbo on the left side right next to the IPR. The ICP is the smaller one of the two. The sensor could very well be bad and I would replace it with an 05/07 and wiring harness. it could be the pump not sure. The swash plate could have moved. There is a timing port in the plate. if misaligned, the pressure could be low or not run at all. there are a few other problem with these pumps.I first look into the crank and cam sensor problems.

 

That doesn't explain the WTS (wait to start coil, glow plugs) light coming on. Whenever the power to the PCM is reset, it will flash the WTS light, even if for just a second or so. That will kill the truck, so will the cam/crank/ FICM sync issue.

 

Thanks for those tips, I'll check on the PCM wiring.

 

Brian posted this in another thread...not sure if it was meant for this one, but relevant info to this thread as well;

DO NOT BUY A harness yet. Others have been where you are and fixed it for less than $30. The glow plug light coming on when this occurs is a short in your VRef.
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Program Torque Pro for VRef. It'll be 5 volts. When this shorts out, it'll kill all the electronics and be just like you've turned the switch off...which is why the glow plug light is coming on.

Start the Truck then do some writing wiggle testing. I would start near the AC. Only the 3 wire sensors have a VRef. When you can cause it to repeatedly stall by wiggling one wire, you've found your short. Replace that pigtail. The ICP pigtail is a common one because it can get exposed to more oil than there others. The oil takes a tool on that sensor.

Hope this helps

 

Ok, so I was out of town for a few days working. I got home today and started by looking at the ICP sensor a little closer. It's an oily nasty looking mess so I'm going to start by replacing that. I ordered an 05 ICP sensor and a new wiring pigtail should be here in a couple of days.
I did a little wiggle testing but couldn't get the engine to stall or notice a difference on my gauges. The KOEO ICP voltage still shows .08-.09, which I know is way low. I will start with the ICP sensor swap and go from there.
Thanks to everyone for your encouragement and replies.

 

KOEO ICP should be .18-.24. At idle it should be .8 or more and it shouldn't be oil soaked at the connector. If that is what's happened, sensor is leaking out the back... replace both just like you planned.

 

Don't use the butt connectors that come with the harness. It would be best to use solder and shrink tubing. Unplug the IPR harness and put everything up where it is easier to work on.