[Fort polk]

Been lurking on here for a long time and am very grateful for all of your help guys throughout my journey with this truck. The problem, i recently did a cup and injector swap as a last ditch effort to stop my truck from shaking at idle and at 40-55 mph. Auto enginuity said i had 2 injectors worn out so i said why not spend my tax money on a whole new set. after being quoted 4000 to have a shop do it for me i figured im handy and could do it myself. Got the cup tool from riffraff, their stainless cups, bitteroot ad stock injectors, frx and hpx all installed over the course of 2 weeks after fighting with a broken injector bolt on and off. (Thanks again to this forum for help with that bolt lol)

Now when i finally got the truck to start it was idling kinda rough, had a knock come and go (figured air in system) and black smoke from the exhaust at idle. I let it idle like that for maybe 15 minutes and was under the impression i would be able to drive it like i stole it and purge the oil and fuel of any air curing all those issues. When i finally got in and drove it tho there was NO POWER. Made 15lbs of boost according to my guage. Egt was at 200* billowing black smoke behind me and it barely made it to 40. Everything i read about this whole process made it seem like i was messing up somewhere.

Fyi i torqued injector cups to 30ft lbs, injectors to 120in lbs and right after that horrible drive threw on some coveralls and gloves to tear it down and double check the torque on injectors. 130in lbs now while hot. Problem persists tho and im stumped. Please help!

 

[cadd]

Sounds like when I did a turbo rebuild and left a rag in the turbo inlet. So check your intake system for something like that.

 

[Fort polk]

Well now thats gonna be a pain lol thanks i will check tomorrow after work and report!

 

[Calif250]

Sounds like when I did a turbo rebuild and left a rag in the turbo inlet. So check your intake system for something like that.

LOL! Thanks I needed a good laugh before calling it a night. Thats why I leave part of the rag sticking out or I cover with plastic wrap.

 

[Fort polk]

Havent forgot about you guys just had a late night but i will see if i cant confirm today after work

 

[Fort polk]

Ok so tore the spider off and looked down the runners. I have a screen and nothing else unfortunately. Been in the turbo twice now and there is nothing there. Started it up with the spider off and still has a knock and black smoke. Is it possible i messed up my injectors already? Black smoke tells me they are firing but one or more is sending way more and not enough air right?

 

[Hydro]

... Is it possible i messed up my injectors already? Black smoke tells me they are firing but one or more is sending way more and not enough air right?

Yup, if any crud got in the fuel side of the injector, the tip may be stuck open
Do you have one injector plug or two on your valve cover harness ?
could disconnect one and see if you can identify which injector is bad
the engine will miss with the harness disconnected, but you should see a difference in the smoke pretty quick
when it quits smoking, you have found the bad one

 

[Fort polk]

Got one but i will give it a shot. Will get back with details

 

[UsedtobePretty02]

Do a buzz test to see if the valve cover harnesses are on correctly. When I did mine, one of the inner electric pins got bent. Truck couldn't barley get up driveway. I did a buzz test and it was real weak on one cylinder. Took the connector off and saw it bend over. Straightened it out and tore down the road with no problems.

 

[Fort polk]

So im thinking hydro may be right about the crud in fuel. I finally got brave enough to drive it to the nearest diesel pump and put 13 gallons of fuel in to top it off. Got to 50mph with 15psi of boost with overdrive off. Egt crept slowly up to 1100 and smoked out everythi g behind me. When i got home i ran a cct again with oil at 211* and it failed 8. Perdel was a 9 at its worst for that cylinder and 1 and 2 were both sitting somewhere around 2 but i cant remember exactly. So my guess so far is dirt was scraped off as i was trying to thread the adapters in for the frx and my lack of cleanliness is costing me.

Best case scenario i go in and unplug 8 and find bent pins or something wrong with the wires. Also koer or koeo (dont remember which pulled this) said number 2 and number 8 glow plugs were bad and it said this before i even swapped them out! Is that pointing towards my relay? The uvch is only 2 years old and i figured it was a bad connection this whole time causing the glow plugs to pop up like that. Never needed them but i dont like having issues that might point towards a bigger problem.

 

[Fort polk]

Ok i installed old injectors with new rings and washers and it drove fine. Sent injectors to bitteroot for overhaul which really hurt. Asked if they found anything and sure enough there was contamination. Didnt ask for details but im gonna assume straight dirt from the frx. Got them back after i went to a range and broke my elbow so ive been sitting on these injectors for about 2 months now and yesterday i got around to installing them again. Not 10 minutes after bolting everything together i had to take an associate of mine to the airport in hiuston. Engine and exhaust manifold had oil on them from purging the cylinders and she smoked for a good 30 minutes before i was sure i wasnt going to have to out out a fire. Think my manifolds are officially nonstick on par with my cast iron now lol. Injectors seemed good but i blew a boot once i really tried to get on it after dropping the guy off at the airport so on these long trips ive been doing i havent really gotten on it in case i end up having to do work on the side of the road with my wife and kids in tow. As such i am thinking that despite putting over 300 miles on the new set i may have air in the oil side still. I only think this because the truck has a very indecisive idle like the ac is kicking on and off but it isnt. Have 70lbs of fuel pressure. No water in fuel or anything. The AC Clutch never engages since ive had the air off in these cooler temps. Even watched it at the car wash after spraying the oil off the engine valley and pan. I dont know whats going on at this point but tomorrkw i have to take it to a local shop and have my brakes looked at because they sank to the floor on the way to the airport and i feel like i have no rear brakes now 😮‍💨. If you guys have any insight on the idle it would be much appreciated. On top of that it sounds like i have single shots sometimes then it smoothes out. If it doesnt get better im going to hook up auto enginuity and see if i can find any codes but i wanr to wait until i can rule out air and get a fair reading.

Sorry for my absence to anyone following!