Thread: CAI Code(s)-Any Fix Soon??
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Old Thu, July 2nd, 2009, 11:22 PM
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As far as a fix goes for your intake situation, the only way around the issue is to get an intake that won't set the codes.

Here is the problem.....


When the Ford engineers designed the intake tract on the truck, the mass airflow sensor was installed and mapped to IT. Air has mass. Any bends, restrictions, turbulence, etc. will cause a DIFFERENT mass airflow volume reading than what the factory air intake has. For instance, if the MAF sensor is placed on the outside edge of a curve in the duct work then the reading from the sensor will measure higher than if the sensor was placed in the inside edge since most of the airflow is forced to the outside edge of the curve.

Ford (as well as Dodge and GM) requires that a KNOWN airflow through the engine be monitored to measure the effectiveness of the EGR system and the particulate filter restriction model. Any time the values are skewed and not within the specified parameters for a given RPM, load, temperature, etc. then a code is going to set.

Sorry about this. The only way that Bill would be able to "fix" the problem is to have the exact Ford airflow specifications and calibrate the MAF sensor signal from the aftermarket intake to reflect what the PCM wants to see....or a lot of trial and error with MAF sensor placement in the tube that closely mimics the factory piece.
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Tuning, PCM flashing, and burning chips for 7.3s since 2008. Repairing all aspects of 7.3L Powerstrokes for 25 years.
Eight 7.3L PSDs in the driveway including a 1994 Crown Vic and 1973 F100/2002 F350. Looking for the next victim.