truck makes loud popping noise (s) when quickly revving it in neutral and when taking off from a stop...sometimes on roll-on in lower gears also.

bent pushrod?

 

Could just be as simple as the fender bolts.

Better check those and see if they are loose.

 

Popping thru the intake.....yeah, check the pushrods.

 

All botls seem to be tight and i just finished putting the valve covers back...what a pain they are...and no bent pushrods.

The sound it makes is similar to popping bubble wrap, but much louder and deffinitely comes out of the aircleaner.

Should have started it with the covers of to see a valve isnt moving...doh...guess I'll pull it apart again.

 

Do you have a stock air cleaner?

you checked the fender bolts as well?
Check the bunch of 4 in the front up on the radiator support, those get loose too.

 

Oh, could always check motor mounts as well, the sound might resonate back though the engine and out the air cleaner. Reving or taking off from a load would make the motor shift.

 

After you pull the VC's a few more times you'll learn exactly what combination of long, short wobble and universal extensions and where to use 3/8 or 1/4 sockets. A stubby flex head 3/8 ratchet makes it real easy to get the rear bolts.

Did you pull the rockers and look at each pushrod or just look to see if they were all seated? Running it with the VC's off would have been a good idea and it doesn't make the mess you would expect, all the oil from the injector spill spouts just collects in the low spot of the head and then drains back to the pan.

 

Just got back to working on the truck now......

Pulled the valve covers again...much quicker this time.
Ran the engine without valve covers and observed all valves moving properly. Good.

But the popping parsists. it will not just do it under load, but also when flooring the throttle quickly and letting off again.
So I had my wife run the throttle while I disconnected one injector at a time. (Just so nobody tries this and gets hurt, shut the engine off before disconnectin or reconnecting the plug at the injector.)
The problem persited until I disconnected #8 injector (drivers side closest to the firewall).
This leads me to assume that that injector is faulty, or at least not firing properly.

Is it possible that the module is not firing the injector properly?
is it worth the effort to swap this injector with another one to see if its the injector or the plug/harness/module?

I also noticed that when it "pops' there is a lot of smoke comming from somewhere behind the turbo. I assume a blown gasket. The smoke is black as is the exhaust when the engine is under load, acceleration or towing, etc...

Could the injector be leaking, dripping? Causing pre-ignition, the popping through the intake, and an over fueling state causing the black smoke?

 

i just had the same problem with my truck this week. i am thinking i may have a bad injector. i replaced the uvc harness and gasket but did not help. i can unplug the back passenger side harness and no change in the motor. i am thinking of rearranging the injectors as well but am not sure if it is worth it. is there away to test if the injectors are getting power and if so what should the ohms be or volts?