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Looking for help on a tough problem
First post here.
I joined looking for some ideas on a tough problem we are having with a 2004 E-350 6.0. The van has 80K and a really good maintenance background. Oil changes are done by the dealer, etc.
The problem is an intermittent rough idle, when you cycle the key often it will run perfect. Sometimes it will still run rough even after a key cycle so it isn't 100%.
The van has had 2 FICMs, 4 ICPs, 2 IPRs, and 2 EBPs in the last 5K miles.
The van is all stock except for an EGR bypass. All the parts on it are Motorcraft.
We have looked at the scanner until our eyes crossed. Here is what we have found:
When it runs good
ICP 575 at idle
When it runs bad
ICP 875 at idle
Our take is the IPR is doing its job perfectly and the issue is the ICP reporting to high a pressure at idle causing the IPR to open more and creating a rough idle. As you can see several ICPs were put in and the problem keeps coming back. It can happen hot or cold.
What else besides the sensor could be causing an intermittent high ICP reading?
Any other ideas, because we're stumped?
Thanks in advance.