Got lazy and didn't order the Dorman FICM PS until last evening so I haven't fixed that yet.. I did install a Thermostat (Napa Lifetime Warranty).. The Motocraft ones were the same prices but only a 1 yr warranty? FWIW, I did drain the coolant into a clean container and then reused it.
While I was in there, I also installed the new (to me) 2003 CAC, my original plastic one has oil literally running down it as I pulled it out.. both the intercooler and intake pipe connections needed to be cleaned before re-assembly.
Started by pulling the Air Cleaner Assembly and the original CAC, set the plastic CAC by the aluminum one..
Oil pooled inside the intake inlet tube, it looked like this inside the plastic CAC and the intercooler connection, but since they are all black plastic, they don't photograph very well.. but still
Damned CCV, it's on my short list of things to remedy, I'll build a catch can and keep a closed system.
Once you get the Air Filter Assembly and CAC out, the coolant drained, and upper radiator hose removed its like an open book, easy to change..
Old Thermostat vs new thermostat.
Reverse removal steps and pretty soon you look like this..
In the attached images I've put the ECT temp chart, looks good now, from 66°f starting, it took 12 minutes to get up to 186° and then it climbed to 192°f and just sat there the rest of the trip. Also attached is a graph showing the difference between EOT/ECT. This chart only shows EOT-ECT, not ECT-EOT, for a while when it was warming up, the ECT was higher than the EOT, but all conversations I've read about the EOT/ECT delta are worried about the EOT being significantly higher than the ECT, so I left that off.
One other graph, just sort of interesting is the 0MPH VGT%.. Since my pickup has a newer ECM strategy on it, the VGT vanes will cycle (sweep) through a large range of motion while the engine is idling, I found it interesting to see it on a graph, but in person if you are standing by my pickup you can hear the exhaust note change when it does this.
I did notice something weird, that I had seen before but considered a fluke. When holding the pedal to the floor to generate full boost (I had to test that the new CAC boots were going to stay in place, didn't I?) the TorqueApp (Android) display and logging both record that I go from 22lbs of boost to a vacuum situation. I am still at WOT and accelerating so there is no way that there is a vacuum, but I need to figure out if this is a flaw with TorqueApp or if a sensor or switch is going out of range. The turbo gauge on the dash continues to display high boost during this issue. I've attached a compete chart of my morning drive and you will see that it did this a few times. I took the data from the first incident and overlayed MPH so you can see that I am still accelerating when this happens. The MPH/boost sample is from a dead stop up to 80MPH as I merged with the interstate