Hi Bob, you were right, the new plunger didn't have any noticeable effect on the way the engine runs. Interestingly, the fuel pressure is lower now though. It still has white smoke and pops. I have also noticed that oil is coming up out of the exhaust elbow as seen in the picture below. It is also dripping oil from where the exhaust elbow meets the turbo. I took one video with it idling. The white smoke and popping are very noticeable in this video. I took another video of it running nearly wide open. It sounds very smooth and the popping is nearly indiscernible. Unfortunately, I don't think I can upload the videos here. I still have not replaced the fuel lines yet and plan to do that soon when I have time for the job. I also plan on pulling the valve cover and checking\adjusting valve lash. Any thoughts or feedback is appreciated.

 

Just for fun run the motor up to where the popping is most noticeable and crack each fuel line at the pump .
You should find the one that is missing that would be the one that quits popping and don't miss worse.
Pull the turbo drain line and check for obstructions to oil flow.
Bob

bluox wrote:

Just for fun run the motor up to where the popping is most noticeable and crack each fuel line at the pump .
You should find the one that is missing that would be the one that quits popping and don't miss worse.
Pull the turbo drain line and check for obstructions to oil flow.
Bob

Will do. I'll report back once I have the results.

bluox wrote:

Just for fun run the motor up to where the popping is most noticeable and crack each fuel line at the pump .
You should find the one that is missing that would be the one that quits popping and don't miss worse.
Pull the turbo drain line and check for obstructions to oil flow.
Bob

Hi Bob, I cracked the fuel lines today and it stopped popping when I cracked the fuel line for cylinder 3. I still haven't replaced that fuel line yet and I haven't checked valve adjustment yet. What should I check next? Also, can you please inform me where the plug is for inserting the TDC tool? I looked around today and couldn't find it. Is it near the starter?

The plug should be either above or below the starter or on the other side below the oil filler.tube.
When you opened the fuel line could you still hear a lighter pop or chuff.
Can you tell if the pop is on the intake or exhaust side.
Bob

bluox wrote:

The plug should be either above or below the starter or on the other side below the oil filler.tube.
When you opened the fuel line could you still hear a lighter pop or chuff.
Can you tell if the pop is on the intake or exhaust side.
Bob

Thanks, I'll keep looking for the plug. Interestingly, the popping completely went away when I cracked open the fuel line on cylinder 3. I tightened it again and the popping came back. I cracked again and it completely went away. I did this 3 times to be sure. The pop seems to be on the exhaust side. This is where I hear it and notice a puff of white smoke when it happens.

bluox wrote:

The plug should be either above or below the starter or on the other side below the oil filler.tube.
When you opened the fuel line could you still hear a lighter pop or chuff.
Can you tell if the pop is on the intake or exhaust side.
Bob

Hi Bob, I'm going to have some time to keep working on the 977 tomorrow. What would you suggest I check next? 

Check your messages.
Bob

If it is easy to do swap injector 3 for one in another cylinder then check it the issue stays with cylinder 3 or moves with the injector. Process of elimination without conducting major surgery on the motor. Good luck.

ChrisE wrote:

If it is easy to do swap injector 3 for one in another cylinder then check it the issue stays with cylinder 3 or moves with the injector. Process of elimination without conducting major surgery on the motor. Good luck.

I have replaced all injector nozzles with new ones and the popping\backfiring still persists. I will swap the one in #3 around just to double check.