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+1 on sensors from "parts stores" being a bad idea.
As far as the P0611 code goes ...... Are you running a higher voltage FICM?
If you run an aftermarket 58V FICM, you will get the P0611 simply because of the higher voltage.
If you watch the video "morning sickness" you can see that scanner values and you will see that I am using standard FICM. The old one had 47.5v reading. Then new one is at 48.5v. That means both are well within spec's. The p0611 is still there on both.
A short video from Ed at Ficmrepair that I received a couple of weeks ago concerning whether good voltage necessarily means good ficm. I had good voltages and terrible cold starts(winter) for a long time. My voltages did finally drop into the unacceptable range and I sent the ficm to Ed for evaluation. After the repair, what do you know, my cold start issues were fixed. What I thought was stiction was a bad ficm.
As an fyi - the MPower is not the only "spec" for a healthy FICM.
That said, you have fixed a fuse issue, an ICP issue, perhaps a FICM issue (who knows for sure if the old one was working properly or not), and a slow crank issue.
That is all good progress. You may now have an issue with injector stiction.
In addition, as I posted earlier, your IPR at 15% when at idle is not right.
Edit -
I'm not surprised at the Ford Service cost. I am also not surprised that they wanted to address the P0611 code. Most shops would just stop working on a vehicle when an owner stated that he didn't want them to address a specific issue such as what is indicated with the P0611 code. I highly doubt that the P0611 would be due to software (if that is what you are thinking).
Also, since you got a FICM from Thoroughbred diesel, I doubt that it would have any "programming" worth saving, unless the "Atlas tune" is an option you paid for.
You mention you replaced a full set of rebuilt and tested injectors. Where did you get them?
The paperwork is back at my shop, I had all the injectors tested at a remanufactorer in Fliint Michigan (don't remember who) and all of them failed. So I purchase the rebuilts from Thoroughbred Diesel.
It seems that the most reliable rebuilt injectors come from Ford dealers. Many other companies sell them, but there appears to be a higher likelihood of failure when they are not through Ford.
Numerous posts on similar issues.
As an fyi - the MPower is not the only "spec" for a healthy FICM.
That said, you have fixed a fuse issue, an ICP issue, perhaps a FICM issue (who knows for sure if the old one was working properly or not), and a slow crank issue.
That is all good progress. You may now have an issue with injector stiction.
In addition, as I posted earlier, your IPR at 15% when at idle is not right.
Edit -
I'm not surprised at the Ford Service cost. I am also not surprised that they wanted to address the P0611 code. Most shops would just stop working on a vehicle when an owner stated that he didn't want them to address a specific issue such as what is indicated with the P0611 code. I highly doubt that the P0611 would be due to software (if that is what you are thinking).
Also, since you got a FICM from Thoroughbred diesel, I doubt that it would have any "programming" worth saving, unless the "Atlas tune" is an option you paid for.
Busted - ya my fault.
Okay. Here is the source of my problems. As I noted, I bought this in a bushel, and put a new IPR in - but I did not check for debris in the port. The port was empty and I just bought a new one and stuck it in - rookie mistake and I own that. Turns out the screen from the previous IPR (which I did not remove) was still in there. When I added the new one and torqued it in, I crushed the old screen and de-seated the cheap IPR. This was the source of all the issues with the noise and the RPM fluctuation. I have removed the items shown, checked for debris, cleaned the port, and put in a new Ford OEM.
I still have some codes for the FICM high voltage and for Glow plug #2 which I will work on. There are also some codes for the trailer brake and 4wd solenoids - but I will get to them in time. This resolves the issue and my concerns.
I do want to thank everyone for their input and thoughts. I do appreciate the direction.
Looking at the options for FICMs at Thoroughbred Diesel, they all appear to be on the inexpensive side (except the 58V ones). Doesn't seem that the option exists for any custom programming on them either. I am not sure I would be all that confident in their reliability. You might get in touch with them and tell them of that P0611 code.