Just out of sheer curiosity... when you first turn the key in the morning, do the injectors buzz? Or do they buzz when you shut the truck off? When's the last time this truck had an updated flash from Ford?

 

Yes injectors buzz when key is turned to start, havent noticed when shutting down... Probably been along time since dealer flash, i stay away from the dealer as much as possible.

 

The 03's originally had it the other way around, so it has had the updated flash at some point. They used to buzz on shut down and they found out it did more harm than good. When's the last time the EGR valve was cleaned?

 

Ive cleaned the egr valve several times since ive owned it, last time was about a month ago. Is your innovative extreme street tune pretty smokey? When i get on it fairly hard it gets pretty smokey in my truck. (Black smoke). I keep thinking its injector issue but with no codes, no lights etc...im just trouble shooting blind. Having the Revx work for over a month makes me think its an injector.

 

Well with HEUI injectors, usually the spool vavle sticks, and it wont fire fuel at all, unlike a common rail injector where those stick, they flood the cylinder with fuel until it melts the piston. So if you have excessive smoke, it's probably not an injector.

My X-street tune would put out a puff until the turbo lit and under WOT there is just the slightest haze, it cleans up real nice.

I've searched quite a bit on this, and there seems to be a lot of different things that can cause the surge. Hard to say. Really needs to be hooked up to a scanner to see what is going on.

 

Its been on a scanner twice already, balance test on injectors etc. Taking it to a very repitable diesel shop here in Cali called Left Coast Diesel. Both times showing good numbers on everything... they can't find anything wrong but agreed with me the first time i brought it there that the idle was erratic. They were the ones who hooked me up with the RevX which worked for awhile...or so I think. They were the ones who did the headstuds, turbo split, oil cooler and bulletproof diesel egr cooler on my truck....The bitch is I can't pinpoint anything really if the truck doesnt kick a engine light or breaks down, especially if scanner tests come up good. On the otherside of things the extreme street tune only gets real smokey when I get on it hard. Power seems a little flat in the bottom of the rpm range compared to the crazy larry tune, but really rockets once mid rpms are reached.... Planning on throwing a Garrett Powermax on her, thoughts on that? Living in California really sucks because of the smog laws, so i feel really limited on what I can do performance wise.... Almost worth it to me to move out of state. Thanks Mdub for trying to help, discouraging issue this one is!

 

When mine has the surge, I found out it is the ICP sensor connection where the wires plug into the ICP at the passenger side valve cover area. when mine has been surging, i can pop the hood and move the plug at the ICP connection and i can get the same surge while moving it. One of these days i'l get to ordering a new sensor..Think they are around $78..could also just be the wire connector instead of the sensor.

 

The ICP could be checked with the scanner. In fact if you have a labtop you can scan it yourself using your SCT and the free software on their site called "livelink". You need to check desired ICP vs. actual ICP, and also IPR duty cycle. I'm not sure if it will help or not, but it will at least eliminate it as a possibility.

 

where is the ICP on the 03 6.0, under the turbo or on the passenger valve cover? How much from dealer? Im about to go just buy one and install to see if it helps... Also wanted peoples input on the Garrett powermax turbo...would like to clean up some of the black smoke the innovative xtreme street tune is blowin, and pic up a few ponies. 6.4 Banjo bolts and updated blue fuel spring? Worth it on a truck that unfortunately needs to be smogged bi annually? Whats the advantage?

 

In order...

ICP is in the back under the turbo on an 03
I see ICPs on ebay for like $60 I think... P/N...
4C3Z-9F-838A
Powermax is a great turbo, made to be a stock replacement, but will support a little more power than stock. Supposed to have a wicked whistle too! Some guys run 155's and a few run 190's with the powermax and put down some decent numbers. You may also want to look into the drop in batmowheels for the stock chargers too, $400.
6.4 banjos are a cheap inexpensive and worth while mod, the stock check valves are just the most restrictive point in the fuel system, so this helps. You wont notice anything per se, but it will keep fuel flowing to those injectors.
Blue spring is to bump up fuel pressure. A little while back Ford released new updated fuel filters. The filter that goes on the frame mounted pump has a new extension to it with an o-ring. They're supposed to seal better and keep more crud from making past, but at the same time they will bring fuel pressure down. Ford released this spring to compensate for that, but decided against telling anyone about it! Anyways, it's a very worthwhile mod.

If you're doing these fuel mods I HIGHLY suggest you get a fuel pressure gauge if you don't already have one. Doing these mods IMO is kind of pointless if you don't have a base line to work off of. I mean, they wont hurt, but you don't know where you're at now. I can't see either mod effecting your smog test one bit.