One of the GPCM connectors was just loose. I got everything bolted back down and no changes. I am now troubleshooting by attempting to compare MAP, EBP and BARO pressures but my TorquePro app only has MAP pressure. I tried making custom PIDs for the other two and they are not reading anything. I need to figure out how to get these two readings to show up in TorquePro.
My CKP sensor will be here this week. I’m pulling the old one today since there is oul around it. It’s not dripping but I know the O-ring is leaking so I’m replacing it to rule it out.
Yesterday I ran diagnostics and can’t get any cylinder contribution or injector codes to pop up, only the Crank Sensor code. I’m still not building any boost at all so I know that’s a big part of the problem. I’m thinking my turbo is suspect and my old VGT solenoid still has a cracked harness on the housing so instead of dropping $150 for a turbo rebuild kit and $400 on a new Motorcraft VGT solenoid I’m just ordering a brand new turbo from Thoroughbred Diesel for $770. I’m also ordering an Ultra FICM with ATLAS 40 and an updated engine wire harness with injector harness. If I keep getting injector codes replacing all the injectors is next.

 

You won't get an EBP reading w/ your 03 model year and the inferred EBP PCM strategy. The PCM just doesn't read it.

I think the new turbo/VGT solenoid (probably the issue is the solenoid) will fix the boost problem.

I thought I posted this, but maybe it was in an email:

To troubleshoot the ckp sensor: check the resistance between the connector on the PCM Pin 30 (harness side) and Pin 41 (harness side). Resistance should be 300-400 ohms.

 

I had a lot of trouble with my early 04 surging, and would occasionally get a CPS error, and I know I have a cantankerous injector #5. I finally tried a new VGT solenoid, and it wouldn't work at all, whereupon further investigation revealed a badly damaged pigtail. I replaced that and the turbo started working right and thing finally threw an ICP error. A friend helped me replace that and we discovered that the pigtail to the ICP was cracked and busted several inches back into the harness causing the wires to short across and/or completely lose contact. After replacing both the sensor and the pigtail, I haven't had a surge since.

 

I was about to post the same thought on this, realizing it's not throwing the code but if it's a pigtail issue where it's not constant it's worth a look.

I know, early builds are a PITA to access anything ICP.

Another thought is to ohm out the VGT solenoid.

The resistance should be between 3.42 & 4.18 ohms @ 73°F
EOT. If the engine is hot the resistance should be between 4.4 to 5.3 ohms @ 200°F EOT

 

Nice post!

Definitely wise to check out the ICP and the ICP wiring w/ the turbo off!

 

Mark I noted the instructions you gave to check the CKP sensor. I already ordered one last week so I’m pulling it today since it’s been leaking oil. Not dripping but the sensor and harness have oil residue on them. You guys have been a huge help and I really appreciate it!

I am about to order the turbo today. When I replaced my HPOP with the billet Dieselsite pump I replaced the ICP sensor with the better one that Diesel Tech Ron suggested. I also replaced the ICP pigtail and IPR screen/o-ring kit while I was in there so I doubt that is the issue but I’ll definitely check it while I have the turbo out next days off. I go back to work tomorrow through next Tuesday so when I get back I should have my turbo, FICM and updated harness waiting for me. Injectors are the last resort but definitely not out of the question. Man we must love these 6.0’s!

 

Ok I got all my parts in and my first day off so I got to work. I got all my tools layed out and got the CKP sensor (crank sensor) swapped and it cured my surging issue! The turbo is still not showing boost and does not sound normal when I hit the throttle but that will be cured when I install the Powermax turbo that came in yesterday. I am going to do a crank sensor removal/installation post when I get some time. It took about 30 minutes...nothing close to what all the videos and posts showed. The only nut I removed was the 15mm glow plug retainer clip nut and the 8mm CKP sensor bolt.

 

Nice. Looking forward to the CKP swap post!

 

Me too! Never did one with the motor in