Originally Posted by Kwikkordead

This day has turned out to be a good one.
A few days ago my injectors arrived from Beans deisel performance.
I ordered stockers with new, not reconditioned, nozzles and plungers.
I had originally planned to come in this Saturday to install them, but the workload at the shop allowed me to bring the truck in and install them today.
I was planning to take soundbytes of before and after the install but I was way too excited to wait.
11:00 am
I brought the truck in and pulled the valve covers, removed the gaskets and the wiring harness's.
I pulled both rear injectors and let the oil and fuel run down into the cylinder. I thought that just putting a shop towel over the hole would deflect the oil that comes back up through the injector hole. I rolled under the truck and proceeded to turn over the engine by hand and immediatly noticed that the oil came out with enough force to blow the rag out of the way and soak the air conditioner. UGH. (Stuff a ton of rags on top of the air conditioner unit.)
Ok, that hurdle is over; pull the rest of the injectors. Routine job.
The tips of the old injectors didn't appear to be that worn out, but they were sure making a lot of noise during operation.
Remove the oil deflector tubes using a 5mm allen and the 3/8" impact gun.
Install them on the new injectors, leave them a touch loose for the final adjustment later.
Remove all the glow plugs.
Install all the new injectors.
Torque them to 120 inch pounds.
Roll under the truck again and turn over the engine for two complete cycles ( 4 crankshaft revolutions) NO LESS. More if you hear oil spurting out of the glow plug holes.
Position some cardboard over the cylinder heads to deflect any flying oil.
Crank the engine over (no load on the starter with the glow plugs out) to fill the HPOP rail. This requires a couple of minutes total crank times. Don't do it all at once or you'll bake the starter. 30 seconds, go clean up your tools for 5 minutes and then come back and crank for another 30 seconds. Repeat a couple of times.
Remove the cardboard.
Install the glow plugs. I had a full set of Bosch part number 80 033 ( OEM ) glow plugs that I purchaced a couple of weeks ago to install along with the injectors.
Reinstall the valve covers, boost tubes, reconnect whatever sensors, connectors that were removed to gain access.
4:00 PM
I cranked on the starter for about 15 seconds and it fired with a big cloud of smoke.

I am immediatly struck with how much healthier the idle sounds. A deeper tone, more even, not a bit quieter. So crisp, so clean. There is NO SUBSTITUTE for new injector nozzles. Sounds like a BRAND NEW engine.

Driving around it's smooth, quiet, powerful, all the hammering is gone.
And the amount of throttle required to maintain speed is cut in half. I am positive that my lost mileage is coming back.
Underway the engine is so much quieter that I strain to hear the diesel noise over my 5" cannon, all four windows down.
I am completly satisfied with the fruit of my labors, starting with the Hutch mod, and removing the quick connects, the oriface mod to completly remove the air from the fuel rails and now the final addition: putting in the fuel injectors.
Life is good.

Originally Posted by ryaneverk2

Removing the foil insulation wrap (installed by Ford to deaden the turbo whistle, shame shame ) from the hot side (driver side) intercooler pipe.

https://www.ford-trucks.com/forums/s...d.php?t=487115
https://www.ford-trucks.com/forums/s....php?p=3657312
https://www.ford-trucks.com/forums/s...d.php?t=488594

Ends up looking like this (pic of my truck's pipe freshened-up a bit ):
http://community.webshots.com/photo/...86590301OtHfpL