After a lot of research and diagnostics. I replaced the FPR and rebuilt the filter head. I got the FPR (Bosch) and filter head rebuild kit thru injectors direct, cost was not bad less than 200 for both.
Since a lot of parts had to be removed to get to the FPR well I forgot to put them back on. Just cleaned the "valve" really good and plugged it back up. Since there are no sensors after the maf it thinks it working. I did manage to get the goo out of the bridge and Y and lost the oil dispenser into the turbo. This truck has 167000 miles on it. It is an 04.5 LLY. It is a EF9. It has a like new LBZ inlet installed on it. While I was waiting on parts to come in I sealed the factory air box from the motor compartment and opened up the front of the airbox to get more cooler air in from around the lights. The block off plate is 3/16 plate and the material used at the egr are the same thickness as the original gaskets this lets you use the original bridge and keeps the orings seated in the Y.
I have only run a tank of fuel through it so far. With no issues or leaks..I am NOT getting any codes. Much quicker throttle response and it appears to be getting better mpg's. The temperature gauge is running about 10 maybe 15 degrees cooler...And the surging is gone and it doesn't smoke as bad as it did before. Very pleased with the performance. I am planning on a lift pump to help the cp3 next. Hope this info helps.

 

was the surge intermittent? are theere any history codes? like a random misfire code stuck in history? what about the wire harness any problems with it rubbing on the alternator bracket?

 

Thanks for asking! HeavyDuty2500
No codes on the message board or scanner.
I checked the harness several thousand miles ago insulated with hose material retaped and wrapped again with thin rubber strap.
The "surge" started about a year or so ago but went away when I changed the filter. Ran fine for several months then started back. At first it was random and irratic. Then became more consistent as it reached operating temperature. I researched through this forum along with several others. Most of the problems with other trucks mines age were consistant with the problems I was experiencing. They were either the fpr or filter head. I planned to loose the egr anyway so I went ahead and took care of both while it was down.
Three weeks ago it lost prime for the first time. That got me to looking at the filter head. But because the problem got worse when the truck got hot that kept me thinking the fpr was ailing too.
When I took the filter off to rebuild the filter head the filter was half full. The orings were worn slap out.
Drove the truck today for an hour on the interstate then idled for 30 minutes. Idle was smooth at about 800rpm never twitched.

 

id have an intermittent surge, truck never had a check engine light but it had a code that was only able to be seen with efi live for cyl misfire. it turned out to be the pigtail for the injector

 

Been thinking about efi live just can't bit that bullet yet. Rewired both 2&7 several months ago. Guess I'll run it and see. So far all good.

 

it can happen to any injector really , even thr goundpacks inside the wire harnes it self in the black plastic cover can go bad. my #6 had to be completely re wired.

 

Would it not run funky, knock, skip or something?

 

It runs better, smoother and cooler. And it's getting better milage? idk...

 

it would have an intermittent knock, chug, and misfire, all of the three things. it had all kinds of funny stuff going on

 

Right now it's running good. I appreciate your advice and suggestions. Till something shows up... I'm gonna let it eat...