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Message: [QUOTE="lubeowner, post: 187998, member: 526"] Ok not to sound like a smart ass but here is what I have learned over the years. Everything is simple. Sometimes we get to caught up in all the big things that "might" have gone wrong that we don't check the simplest things or we run into a "thought I did" or "thought he did." Or we rushed through the simple tests and the outcomes were tainted for whatever reason and we didn't even notice what a little thing we over looked. Now as I say this don't take this the wrong what but there is a simple answer to your problem. So simple that you are over looking it and moving on to the hpo system and that has probably tainted your testing. I have seen some pretty stupid things on some of the truck brought to me and I sometimes forget to keep it simple. 99% of the time it always comes back to the most basic things. Since you are certain this is fuel smoke.... The simple answer is you are getting too much fuel into a cylinder or a couple cylinders. So there is no need to look at anything other then the fuel system. Not the HPO system, tuning or anything other then fuel. Also turning off or unplugging an injector is going to get you no where in testing as you will still be getting the extra fuel. So those tests are pointless. You either need to do a cylinder contribution test. These can only be done with a Ford IDS, Snap-on scanner with update 11.2 or newer and Auto ingenuity. If you are using a Matco or OTC Scanner or the Snap-on has a older version then you are out of luck. So to start with, are you running a cylinder contribution balance test once you get the truck started? If you had this issue should be very easily diagnosed to one cylinder or one head. So remember to keep it simple. All this fuel can only be getting into the cylinder by one of two ways, through the injector or around the injector. Now through the injector should have been ruled out by changing the three sets of injectors. The only way through an injector is with a bad injector. Are you certain there is no possible way all three of these sets never had the same injectors in the batch? Like did you replace with a 100% different set or did you pull them send them out, have them tested got them back and put them in? There is most commonly only one way to get fuel through an injector and that is with a leaky nozzle. There is a couple others that I have seen and I will address them later as the will show up as an around the injector problem. If the injectors are 100% ruled out as bad, then the fuel has to be getting into the cylinder buy going around the cylinder. This can only happen by a bad injector install or a bad head. Also it needs to be understood that if 65 psi fuel can get in then 2000 psi combustion can get out. So if you are certain that fuel is not going through an injector, then it has to be going around it. If this is the case you should be able to test that combustion is coming out. I know you said you did the balloon test but maybe you did something wrong? It is this simple, either you have a bad injector or you have fuel getting in around the injector. Either should be tested for with a cylinder contribution balance test to obtain a starting point. If you have one high contribution cylinder and the rest are all good and that is where it stays then you have a through injector problem. Also I have seen many times that one high contribution will bring the cylinders on each side of it up on the scanner as well. If the contribution starts at one or two cylinders then gradually picks up more then it is a around the injector issue. Now things I have seen that fit into the around the injector that I found wierd. Truck with less then 500 miles on it since Ford put in 5 new injectors. Could watch the balance test and it showed one cylinder low then a second then I would lose the whole bank, then start seeing the other side getting off and the truck would die. Pulled the upper fuel bowl to find it was getting air into the fuel system as the level was very low. So I pulled the center plug out that goes up into the filter, if you don't do this then the little plunger will come up and you can't see the compression coming back. So jump the starter to crank it over and sure enough I get little puffs out of that bank. So I pull out the injector that was the first to contribution balance off. Looks perfect. Not one trace of the combustion going through it anywhere. So I figure it must not be this injector so I pull the other 3. All look perfect as well. Now I feel stumped. So I put if back together but I moved the suspect injector to a different hole. Start the truck problem now starts in the whole I moved it to. So I pull that injector again and put in a new one. Problem gone. Another truck had new injectors put in himself and the place that he got his injectors rebuilt from put a spool valves on backwards. Due to the little alignment notch the injector would not go in all the ways. The tilted injector then didn't seat right in the cup and ruined the cup. Another truck we put some brand new heads on it and for some reason the injector cup holes seemed to be tighter then they should be and that didn't let the injectors seat properly. What we noticed on that was when we tried to pull the injectors out to recheck, some did not pull up with the hold down as they normally would. Thought it was our fault as an install error. After about 2 months of dealing with this I got anther set of heads and put on his truck and the problem was gone. I also had a truck that had the injector body not tightened all the way and it way getting combustion up through the injector around the nozzle and the body. Didn't burn any o-rings and the copper gaskets looked perfect. Anyways, fuel is either getting in through or around an injector. Have to figure that our first. [/QUOTE]