I have an '03 6.0 with 240,000 miles. At 215,000 all injectors, EGR, and EGR cooler were replaced. A few miles ago (800-900 maybe) I replaced the ICP sensor because the engine would intermittently jump up to 1000 RPMs for a second or two while stopped at a light, then suddenly drop back down, and I could sometimes feel it surge at highway speeds. Replacing the ICP fixed the problem, improved the fuel mileage and it ran perfect until yesterday, when it started the same problem again, but much more frequently, and more noticable at highway speeds. Had the diagnostics run, and the mechanic (not a Ford-trained guy) says it shows a problem with the EGR and #1 injector. I've been running with the EGR unplugged, but when the problem reappeared I plugged it back in - no difference. Since the symptoms are almost identical to the prior ones that the ICP sensor fixed, and the injectors and EGR only have 25K miles (and I don't see how one faulty injector can cause these symptoms - when it speeds up suddenly it runs smoothly, not rough), I suspect the new ICP has failed (I bought it on E-bay). Can it cause those trouble codes to appear? By the way, the Check Engine light has not come on at all.

Thanks for any help or advice!!

 

I had ICP sensor last about that long.The new sensors are built different than the older ones,the new ones have a solid plastic back/top that is sealed around the edge of the metal and the old ones have a silicone like seal at the back/top where the harness plugs in.I had no codes with the same ICP symtoms.

 

Thanks for the quick reply. I'm about 90% convinced that's the problem. I can't remember exactly how the ICP I bought on Ebay was made, but chances are it was the old style, since I'd had it for several months before I finally got it installed. I tried to do it myself but my short arms just won't reach up there. Unless someone comes up with a better suggestion, I'll probably get another one installed. Again, thanks for the help.