Originally Posted by bismic

Sorry to suggest all the work on the fuel and then it still does the same thing, but you certainly do not want the dealership doing this and charging you for it.

Some other things to try:

You might try pulling the ICP wiring harness off and see if that makes a difference. The ICP sensor on the 2003's is known to get oil soaked and go bad. Your symptoms did not sound quite like a bad ICP, but who knows.

It also could be wire chaffing - I will post some links in a little bit.
Wire Chaffing Locations
http://www.thedieselgarage.com/forum...1&d=1208412696
FICM and ICP harness recall
http://www.forddoctorsdts.com/articl...icle-05-13.php
http://www.forddoctorsdts.com/articl...icle-05-11.php

Are your battery voltages good? Low voltage can really cause some issues w/ the engine due to the way the Fuel Injection Control Module operates.

Is there any way you can verify that you have good fuel pressure (ie may be a bad HFCM pump)?

Have you ever had your truck re-flashed at the dealership? If so, the flash most likely eliminated the EBP sensor from being an input to the PCM. If not, it could be a bad EBP esnsor.


Here is a collection of Ford advice on rough running:

Wire Chafing Issues:
A variety of driveability issues can arise from chafing/shorting wiring, such as crank/no-start, stall, running rough, misfire, buck/jerk or lack of power. The most common location for this is the valve cover/cover bolts near the FICM or the intake manifold bolts where the harness routes under the air intake hose. The harness should be rerouted and any chafe points insulated with rubber vacuum caps. Other chafe problems can occur where the sensor harnesses route around the valve covers, thermostat housing, idler pulleys, glow plug relay bracket, and near the accelerator pedal assembly (adjustable pedals), and also near the PCM by the battery and near the relay box brackets at the left rear corner of the engine compartment. On Econolines, also inspect at the top edge of the computer, along the oil dipstick tube bracket and auxiliary A/C lines. Broadcast Messages 1407 and 3077.

ICP Sensor Problems:
This is now covered by Customer Satisfaction Program 03B05. It applies to trucks build through 2-3-03. The program will be in affect until 12-31-05. Ford is authorizing a free oil and filter change tunder this program until 12-31-03.
Some 6.0 PowerStroke engines may exhibit rough/rolling idle, poor idle return, lack of power, injector fault codes or excessive smoke. This may be caused by the ICP sensor reading incorrectly. The ICP sensor and connector terminals should be inspected for damage (the ICP is at the rear of the engine, under the turbo), and the sensor circuits checked for opens or shorts. With the engine at operating temperature (engine oil above 180 degrees), the ICP sensor signal should be 0.16-0.28 volts (less than 70 PSI) with the key on and engine off. The engine needs to be off for at least two minutes for this test. If the ICP signal is not within this range, replace the sensor with P/N 3C3Z-9F838-EA.

Runs Rough, Lack of Power, Oil Level Overfull/Fuel in Oil:
This may be due to fuel leaking through or around one or more fuel injectors. There is a comprehensive TSB that has step-by-step diagnostic procedures to isolate the problem to determine in which bank the leak is occurring and to identify which injector and whether it is an o-ring or an injector failure. Note: If more than four quarts of fuel is present in the oil, the turbo charger shaft end play must be inspected. If end play is greater han 0.004", or if the compressor fins have come into contact with the housing, the turbo must be replaced. After replacing any leaking injectors, the oil and filter should be replaced and the truck driven 20 miles. These steps need to be done twice more before releasing the vehicle.
TSB #04-9-3.

Rough/Surging Idle, Excessive Smoke, Lacks Power, Poor Throttle Response:
This may be accompanied by DTC P2263. Inspect all intercooler hoses and pipes and exhaust system before the turbo for leaks. Ensure the oil level is correct there are no oil leaks and all electrical connectors are secure. Check the ICP sensor as in the following bulletin. If no problems are found, make no attempt to repair the condition. Engineering is investigating. Broadcast Message 0225, 0471. SSM 16488.

Lack of Power, Hard/No-Start, Runs Rough on Delivery:
Air in the HP oil and fuel systems may cause the above symptoms. The vehicle should be driven 30 miles to purge the air from the passages. If this does not resolve the concern, use WDS to command the variable geometry turbo actuator to cycle. If the concern is still present, continue diagnosis. Broadcast Message 0211.

Originally Posted by mommadiesel

the truck was starting without any problems and there was no excessive smoke. Just a really rough consistant idle.

Originally Posted by bpounds

I can't add anything of value, but you've got my curiosity up. Did you actually drive the truck to try and warm it up? Or are you just starting it to see if the idle clears up?