Thought I'd give an update on a few things. 1) How it's running with the new injectors and 2) A warning on something I found, and 3) For those changing injectors (and setting lash) for the first time, a couple thoughts.
1) I have run about 1.5 tanks of fuel with the new injectors. To recap - I went with 0.5 BBI's. The truck idles a little rougher but runs very smooth. I get a little more smoke - both haze/white at idle, and a lot more black when I punch it. The exhaust smells a little stronger. I am running unloaded/no towing and feel low RPM power about the same but better power in the higher RPM, better response hitting it hard from 40-70 miles per hour. I've put very few freeway miles on so still need to see what happens there. Surprisingly, with my mostly city commuting the first tank picked up mileage by about 10% (14.3 to 15.9). I was very meticulous torquing the fuel tubes, but just in case the additional white smoke/odor is a little fuel getting past that joint, I am going to get an oil analysis to make sure (no obvious fuel dilution but I thought the oil in the rocker box smelled a lot different after running the new injectors for a few minutes, but could have been loosing my mind by that point). Lash is set good.
2) One extra little fun I had when putting the injector wiring harness back on, one of the little BLACK cable ties holding the wires to the plastic frame broke and fell into the rocker box filled with BLACK oil. I did not like the thought of that getting churned through the system but man was it hard to find, back on number 6 of course so I had to fish around blind to pull it out. When I did a little tugging on the rest of the wires I found that all of those cable ties were deathly brittle and broke at the slightest stress. Normally those ties never see any stress, but I caught a wire reaching in to #6 and that was all it took. Obviously the heat made the ties brittle, and I wanted to replace them with something better. Found some higher temp rated ties and tested them with a heat gun. Ties were rated to 338 degrees F, I hit them and some standard ties with a 600 degree heat gun. Both shriveled up, but the good ones did not become brittle, while the normal ties broke up like an old cookie. Pictures below of the factory black, new blue, and white test subjects. This is a quick replacement you might do next time you have the valve cover off.
3) First timers' observations. This thread (and related past threads) was invaluable in helping me understand what I as in for, helping with questions along the way, sharing tips, and getting information from suppliers even. I really want to thank everyone again for all the help. It was a big job but doable. I spent about three days, working at a slow, no-rush pace, swapping out the injectors. Most of the guys on here will probably laugh at that but I'll admit it for your benefit. I am actually more embarrassed at how long it took to set the valve lash. This was all about technique, and it took a while to get mine down. I did it twice (checked and reset after the first handful of miles) and it was shockingly faster the second time.
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