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When you throw the programmer to it, again I am not familiar with the one you are using, injection is changed and how the VGT turbo vanes close and open along with EGR operation turned off. You could be moving more air with the programmer on start-up ect.
Is the blue smoke after sitting over night or at anytime? Seems injector related to me.
usually cold start after sitting all night. as long as engine is ambient temp on start it smokes until aprox 1/4-1/2 on temp gauge. warm restarts no smoke. never smokes with chip aside from minor puff on start.
i'm no expert but i have to shy away from turbo being problem as it had a complete new turbo aswell i swapped in another good known turbo just to see- still the same
The best plan would be to let them pull it down and inspect it. Sounds like it had a serious overheat and inspecting everything would ensure you have a reliable ride. It does have 3 compression rings + oil ring. One could be broke and still make good pressure.
With over 10k miles on it since the overheat a broke ring would have likely marked up the cylinder pretty good by now. Pull the head and insp cyl bore from the top (don't drop pan or pistons/rods. Disassemble heads and insp guides/seals.
Pull the valve cover and verify good oil flow. Inspect rockers and pivots. Insp the valve guides using the wiggle test and replace seals.
Load the pup and drive it. If it's seals it will stay about the same. If it's a ring or guide it's going to get worse.
I think oil at the manifold is a good indication of where the problem is. If it were a ring issue it would be much worse at this point and pressure would be down at least a few lbs on that cylinder. Also, oil would have to leak up into the cylinder after shutdown. I would verify there's good lp oil to that cyl and check the guide.
i'm no expert but i have to shy away from turbo being problem as it had a complete new turbo aswell i swapped in another good known turbo just to see- still the same
Just telling you how to go about checking it thats all
No sense splitting heads if you still have the tuner in it. Could be injectors and the tuner changes the IPR, or it could be EGR and tuner turns it off. The tuner will just mask the problem.
i'm open to any advise/options anyone has. i really dont need chip in it, just didn't think that the tuner could change enough settings to stop the smoke if it really was an internal problem? ford tech says no to injector orings but who knows. its on my dime now as warranty ended in may.