Sooo...

I am new to the forums but have general and extensive automotive experience. This is my first diesel, but I have learned a whole lot since owning for almost a year.

My truck has 248,000 miles on it. When I bought it it ran pretty good and has no leaks, pretty solid.

I started experiencing problems late summer. Truck would start running rough, eventually dying. Narrowed it down to the ICP and changed it out. After this swap, I had what feels like a miss... Only around 1025 rpm and again at around 1700-2000. I decided to go all out and do some upgrades to the top end. These upgrades and mods were done because I noticed several things done poorly by the previous owner. The turbo was an Ebay turbo, fuel line to pass head was cut and spliced, leaking IPR, it was really filthy in the valley making it hard to see anything that could be wrong on top.
The upgrades and repairs I did are as follows...
Adrenaline HPOP
CNC Fab lines and x over
Sinister ICP
New IPR
Wicked Stage 1 Turbo/basically Garrett 38 w/WW2
4 inch straight exhaust leading to bigger tip(was that way when I bought it)
EPB delete pedestal
New CPS
New clamps on turbo inlets and outlets
New pass bank fuel line
Blue spring kit and rebuilt fuel bowl
Now with all of it back together I had been driving it for the past two months... Problem is that the miss is still there and now it is worsening. The truck drives okay for about ten miles then loses power significantly, eventually dying altogether. Restarting right away the problem still exists, no power or throttle, until dying again. If the truck sits it runs fine after cooling down, but will do the same thing again once warm. There has always been an Edge Evolution tuner on it, but the problem is the same whether stock or on any tune. I have white smoke, which leads me to believe fuel issue. These symptoms together I cannot find on the forums. I think injectors but am not sure. I have no problem putting the bux into injectors but i don't want to do tat and have the same problems.
my symptoms...
Rough idle
Rough throttle at 1050 and between 1500 - 2000 rpm
White smoke at startup and continues til warm
White smoke at full throttle and when running poorly
Truck loses power and eventually will not run
Truck does have loud knock, injector knock, on pass bank
that gets louder after coming to a stop when driving.
Any help here would be great.
I have deducted o rings and or injectors but just dk.

Oh yeah... Through all of this I have a friend with a Snap On programmer. Cylinder cont test was great, especially for the miles on the truck. Buzz test perfect, I know thats only the electrical side of the injectors though. The ICP was replaced because of oil in the connector.

 

Welcome to FTE.

Were the sensors you replaced Motorcraft OEM sensors? These trucks do not like aftermarket sensors! If you used aftermarket sensors pull them and replace with OEM. THEN start troubleshooting the problem.
‘Since you have a problem with the truck running,
Rule 1) Completely remove the chip from the PCM.

The following assumes you have OEM sensors:
Is the tin nut tight on the IPR?
‘The next time it stalls take a can of compressed air turn it upside down and spray the CO2 on the IPR, then try and start the truck …
What is your fuel pressure?
Does the truck have any codes?
‘Oil level?
When the truck is running use a IR thermometer are both manifolds close to the same temps?
Have you checked the 42 pin connections specifically underneath for chafing of the wires?

 

OEM sensors except the ICP, actually may be OEM just got it from Sinister Diesel. Yes nut is tight on IPR. No codes other than epb which would coincide with the delete. I have not done the manifold temps but can do that. My concern is that the truck had the same rough idle, sporadic rough running around 1050 and 1500-2000 before I did the work. I will run over the wiring to the UVCHs again but I checked them pretty thoroughly before taking it apart and again after cleaning it all up. The gaskets looked new so I did not replace them. All the injectors we're pumping oil out of them as well before i tore it down. I well check the temps on the exhaust manifolds

 

Checked manifold temps, leading me to believe what i thought was suspect all along. The drivers side is 20+ deg cooler than the pass side. I did not check individual cylinders since the temp difference was so dramatic. I have not been driving it, i just go out and start it every couple days since it's cold here. Once it's warmed up, exhaust manifold temps around 150, it is smoking...white smoke. Stock tune was put back and the programmer is completely unplugged, no chip. Ideas? I would hate to spend a couple grand on injectors as the problem still exists. I did find a small oil leak i assume coming from the silicone boots on the spider. My intake plenums are crushed and i plan on replacing them and the boots since i know they are prone to leaking after this amount of time. The exhaust smells heavily of diesel. There is also a visible shake to the engine at idle, if you are looking at it under hood.