A small amount of leakage is no problem, a lot however, and it will drip down the nozzle and harden on top of the part-> nozzle collision-> skipped steps-> failed print. The acceptable leakage depends on how long you plan to leave it unattended. When it's really bad (too much teflon tape) I've had good luck baby sitting it, and wiping the drool off with a Q-tip.
Next time you take apart the nozzle use Permatex High Temperature Thread Sealant (I read about it on the boards here) instead of teflon tape. I've been getting good results with that. You can get it at any auto parts store. Be careful to clean any extra out of the melt well before you reassemble.
The item I bought was 6mL and the part no. is PX #59214
Kyle
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Daid 303
My nozzle is black from the PLA on it. No problem.
But smoke might mean you are printing at 250C, which is a bit high for PLA. I don't go higher then 230C with PLA, and then it flows like crazy.
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