I have been getting way too much smoke, even with stock fuel programing. If I accelerate slowly, or even typical no problem, but if I get into it too quickly, not mashed down, just a touch more than typical, it rolls the coal.

I initially thought I had an air leak so I started checking the system out, and this is what I found the following.

2 very small leaks in the IC, bought a BD

1 rear nut from upper turbo missing, other could spin with my finger.

Waste gate actuator rod had come undone (I thought this was the "smoking gun)

Waste gate cover, warped and leaking (replaced with 1/4" thick one)

Upper turbo to hot pipe leak, taped sandpaper to a granite slab and flattened both mating surfaces, reinstalled with a very thin layer of axle grease, re calibrated V clamp.

I cleaned everything up very well, tightened the snot out of all the clamps, really spent a lot of time doing everything right. Got ever thing back together, really expecting that my problem had been solved, but it is not! Maybe a slight reduction in smoke, but still get enough smoke tat the car behind me moved out of the way on a freeway on ramp when I accelerated a little aggressive, I was already rolling about 30mph, had 20 psi boost, and didn't mash it, not a cloud but a very thick haze. I really don't think there should be that much smoke under these conditions.

I checked the turbo bearings while out, all was within specs

The only other unresolved possible problem is engine oil in the intake tract, IC coming from the turbo, but from what I have heard that is typical.

Also when it rolls the coal it doesn't feel the same as when you turn up a tuner, it just feels like regular to simi aggressive acceleration.

What do I check next? Injectors? they are to OEMs with 140K hard miles on them on stock filtration? How do I check them. I need to use my truck for the next 2 weeks, I can keep the smoke under control, but am I risking a bad injector / hydro lock? How does one test injectors, would taking it to the dealer and have they run their diagnostics on it help? Compression test time?

 

Do you have a rail pressure gauge. This is the first place you will see a tail-tail sign if you have an injector issue with a little lower than normal RP. With 140K I will just about beat you will not be in spec. You have to take them out and send them to a reputable company to see what's going on with them. Either F1 or Exergy.

 

If it is only one injector you can try capping off at the rail until you find the one causing your smoke. I usually run a injector percentage test to help me locate which injector is failing. I stress the injector with the FCA disconnected that will show a bad injector fast but don't run it like that for very long you'll be at max pressure, I usually check the pressure limiting valve at the same time for leakage. Good injectors will show 100% Bad injector will be 80%.

 

Thx for the replys

Exergy 50 hp on their way. Thinking of doing head studs, and valve springs while I am in there. How big of a chore are studs? Valve springs?

 

You have to pull the injectors to do them so I would do them both.