Very interesting issue

[sandm849]

Ok so the truck I am referring to is the one in my signature. I bought a dp f5 chip off of a user here and sent it to dp to have it reburned for my PCM and also have a couple of tunes put in. Installed the chip making sure to thoroughly clean the PCM contacts where the chip goes. Truck starts and drives fine in all positions until I turn on my headlights. Yea I know sounds crazy. Sometimes I get the water in fuel light, glow plug light, and ses light. I also lose all pedal response for roughly five seconds. Sometimes it will stall the truck. If I flash my high beams it does the same thing and also stalls the truck usually. I flashed somebody on the highway the other day and my truck died. So this is a dangerous situation. Also I do have an hid conversion on this truck that has been on it since I bought it. These problems seemed to start right after the chip install. Like I said all is good until I turn on my headlights and it isn't all of the time. I'm planning on taking out the chip this week to see if that problem goes away. I did pull codes and I had p0605 Icm Rom error on the koeo test. p1396 glow plug monitor bank two and p0603 icm kam error as memory codes. Any ideas? I was thinking something along the lines of rf interference or a bad diode in the alternator causing feedback since it's when I turn on my headlights but idk. Or possibly a corrupt file in the chip? I contacted dp late yesterday so hopefully they will have an idea. Figured the more input the better. I used to work at a ford dealership on diesels in the 6.0 era but this one has me scratching my head for ideas.
Thanks in advance.

[sandm849]

Well took out the chip and no more problem. Double checked my terminals on the PCM and look as they should.

Just talked to dp. They have seen ground issues with the hids cause this problem as well as the cable for the chip. Will get around to looking at it late this week or mid next week. Will post updates if anybody is interested.

[VolTone]

Please do - I am concerned a bit since I have HID's and a DP F5 coming to me Monday.

[sandm849]

What kind of hids do you have. I have ddm slim 35w in mine. Grounded one of the wires that figured may be the problem but did not fix it. Looking into a couple more things next week.

^^^make sure all of your grounds are excellent as they have seen this cause this problem.

[sandm849]

Well no solution yet. If just the chip is in the PCM with no cable I have zero problems. Installed a new cable today and still have the problem. Tried it with the switcher disconnected and problem is still there. So chip installed no cable=ok. New or old cable with switcher or not=problems. Dp still trying to find a solution for me. Any ideas people??

Voltone. How did your stuff work out??

[sandm849]

Anybody? I have a couple more things to try but so far no solutions from dp or otherwise.

[precisionauto]

I would suspect a ground problem. Check a wiring diagram and see if there is a common ground between the headlamps and the PCM.

[precisionauto]

G100 is a common ground shared by the pcm and the headlamps, I would start there.

G100 engine compartment, rear, LH side - Gasoline engines
G100 engine compartment, rear, LH side - Diesel engines
G101 engine compartment, LH side
G102 engine, RH side
G104 engine compartment, right fender
G105 engine compartment, front, LH side
G106 engine compartment, RH side, on frame rail
G108 engine compartment, RH side - Gasoline engines
G108 engine compartment, RH side - Diesel engines
G109 engine compartment, LH side
G111 engine, top
G200 behind dash panel, center
G201 behind dash panel, center
G202 behind dash panel, center
G203 under dash panel, RH side
G300 LH A-pillar, behind trim panel
G301 Vehicle interior, LH side, after C-pillar
G400 vehicle underbody, rear, chassis side member, LH side
G403 RH D-pillar
G900 LH C-pillar
G901 vehicle rear end, roof

[sandm849]

Thanks for the ground info