I just swapped nozzles, then had an injector going (putting white smoke out the exhaust). I did the injector kill test with the DRB from work. narrowed down the cylinder and replaced that injector. Now after i swapped the injector, i have a miss and lots of smoke coming out the exhaust. I was extremely careful and clean this go around. I tore it all off, inspected it all and cleaned the parts and put it back together again, and still the same thing.

Any ideas? I didn't grab the DRB for the weekend (and kicking myself for it now)

 

Cross tube not seated.

 

I thought if the crossover tube wasn't seated that either the truck wouldn't start (unable to make rail pressure) or that you would be making oil. I'm going to swap out to the old stick this morning, and make sure the problem follows the new injector.

Sometimes I wonder why I have to be obsessed with wanting more out of my truck.

 

the cross tube is not seated right i had the same problem out of mine the first time i would check that before i put the old injector back in it. if it is still doing after you check it then replace the injector. the truck will start with out the tube in right and it does not make oil if the tube is not seated right it sends all the extra fuel out the pipe.

 

Did you use the proper procedure?
Install fuel injector holdown clamp (mounting flange) bolts. Do a preliminary tightening of these bolts to 5 N·m (44 in. lbs.) torque. This preliminary tightening insures the fuel injector is seated and centered. After tightening, relieve bolt torque, but leave both bolts threaded in place.
If required, assemble o-ring to injector fuel supply connector. Lubricate connector bore and threads. Install fuel supply connector into cylinder head by engaging locator into groove and push to engage o-ring. Install fuel supply connector nut (fitting) into cylinder head. Do a preliminary tightening of this nut to 15 N·m (11 ft. lbs.) torque.
Perform final tightening of fuel injector mounting clamp bolts to 10 N·m (89 in. lbs.) torque.
Perform final tightening of fuel connector nut to 50 N·m (37 ft. lbs.) torque.

 

I got it (finally) I followed that same torque procedure that you listed. I swapped back to the old injector with the stock nozzle and all the problems cleared up, so i narrowed it down to the nozzle. i pulled the needle out of the 90 hp nozzle and it seemed like the tip was broke off compared to the stock one. It also seemed like it was a lot harder to slide back and forth, so i swapped to use the needle from the stock nozzle and the nozzle from the 90hp one.

I really wasn't suspecting the nozzle since it was new when i put it in.

Thanks for everyone's ideas. No one is as smart as all of us.