50,000 miles on a motorcraft rebuild, .020 over. Terminator T-500 HPOP. 3in round down pipe, 5 inch exhaust. Rebuilt ZF5 with ~2000miles with all brand new clutch components. Super Duty Electric Fuel pump with an aeromotive fuel regulator set to 70psi. I was out playing on some trails one night, on my way home noticed the truck was smoking badly, blowing clouds of white smoke, steadily smoking at idle. No smoke blowing out of the oil fill cap. I initially thought I had oil in the exhaust leaking from the Y-pipe, so I rebuilt the turbo, new seals, bearings, and compressor wheel. Still smoked like mad when I got it back together. Still had fluid leaking from exhaust flanges, determined that its was diesel, and the smoke was all fuel. Thought it must be injectors. Had the injectors built to 160cc with stock tips, guy who rebuilt them said I had 4 broken injector springs and 1 broken tip. I found the issue for sure this time!! nope. got them back, put them in, still smoking. Drove it 100 miles attempting the dry the cylinders out thinking maybe it just still had oil in a cylinder, still smoking. Was throwing quite a few codes so i put brand New MAP, BARO, and Exhaust Back Pressure sensor. I swapped PCMs, its has a two year old IPR, and it has new Valve Cover Gaskets. The truck is very doggy and smokes like crazy down low, but once it gets to about 2800rpm, it will come to life, stop smoking, and go from 2psi to 16psi boost, and rev out, then after the shift, the same exact thing. It is now throwing an "Injection Control Pressure Lower/Higher than desired" that then greatly reduces power. I cleared it probably 5 times, would get power back, then when I had it WOT the check engine light would pop back on. . Im seeing Injection control pressure at ~600psi at idle, and only 2200-2400psi at WOT. Oil was just changed and levels are good. I'm lost now. I really need some help. Any suggestions?

 

Where the O-rings on the injector lubed good when the injectors were installed? With the tranny in neutral rev the engine to around 3000 rpms. If the rpms climb to 1800-2000 fairly smoothly, then stumble and white smoke pours from the exhaust, then slowly climbs to 3000, this points to some bad o-rings. If they weren't lubed well enough, they can roll and be cut. If cheap china made O-rings were used, this is even more likely.

 

 

Each injector I put in I made sure I gave a good coating of Rotella before putting in. A majority of the fluid was coming from the passenger side manifold to up pipe flange. So I pulled the valve cover and pulled glow plugs to inspect, just to see if I could find any anomaly. Cylinder 5 glow plug had an oily mixture all over it, it was the only one that wasn't clean on that bank. So I pulled the injector and put all new orings and brass washer. And it revs fairly evenly, but quite slowly to around 3000rpm. Tomorrow I can try again and pay more attention to that. The IPR duty cycle was about a percent low at idle and at WOT. About 8.5% at idle a around 18.5% at WOT in neutral. What could the explanation for how it spools the turbo way up high and cleans itself out?

 

I may have mislead, it was cracked, not broken off, if that changes your opinion? And it smokes almost identical to how it did before I changed the injectors after.

 

I agree with Mike (fordpride)

 

Its most likely the two year old IPR .

 

After you clear codes and the CEL is out does it quit smoking and run right? As long as the CEL is out? Do you get the same codes every time, what are they? What are you using for a scanner/monitor?

 

It doesn't run perfect, but it definitely gets better. I get a repeating "Injection Control Pressure Higher/Lower than Desired (Engine Running)" code any time I would go above 3/4 throttle. I am using an Autoenginuity program.

 

I am planning to pull the injectors and take them to the shop that rebuilt them to have them re-tested. The IPR is functioning about .5% lower than what is recommended. Its function at about 8.5% load at idle, and 18.5% WOT in neutral. Would this this be enough to cause all of the smoking?

 

does the smoke smell like fuel?
if it does then I would look at injector or compression issue. If doing injectors, might as well do a compression test prior so you know whats going on

 

Plan to compression test it Friday. Injectors going in on monday. I'll let you guys know.

 

Only 200psi in Cylinder 5. Looks like I'm pulling the motor.

 

That's not good but at least you found the reason.

check for bent push rod?
have a bore scope?