I had to pull my powerstroke out to reinstall the oil plug on the inside of the timing cover. I figured while I was there & since the engine was on the floor, I would replace the injector o'rings. After I installed the engine, it took a very long time to start. It had a rough idle & smoked like a freight train. It was suggested that I take it for a drive. I ran it about 50 miles & it still would not idle smoothly & smoked worse since it was hot. Smokes at idle or underway, doesn't matter. Before I replaced the seals in the injectors, the truck ran really well, no smoke. One thing I did notice was that when I showered down on it, one cylinder started really rattling, so loudly that I backed out of it each time. Never got any better. I convinced myself that I had damaged an o'ring, but I cannot find a bad one after I removed all eight. I might add here that the thought struck me to pull the fuel filter first & check for oil, (after I pulled the injectors) but I was frustrated. The fuel filter showed no signs of oil. This is my first powerstroke, so this has been on-the-job training. I need this thing so I can trailer some tractors to an antique pull Saturday, so please help! Thanks!

 

Did you make sure to lube the injectors when putting them back in?

It does take some time to get the air out of the system... 50 miles might not have been enough...

Also, are you sure you seated and torqued the injectors to spec?

 

Check and make sure the injectors are seated completely.