Pull the spark plugs, check if they are fuel soaked or sooty. Maybe you got some bad injectors. Or are they the originals?

Your O2 sensors are either saying that one bank is super rich and the other is lean or they aren't reading properly.

 

They are the original O2 sensors (120,000 miles). I plan to replace them but they worked fine before the rod broke so I am thinking there is something else wrong. I am going to pull the plugs and check them them at the same time I do the compression test. When I had the motor apart, I cleaned the tips of the injectors with injection cleaner and Q-tips but they really weren't dirty.

 

This seems to be the real issue. I am going to test the wiring at the O2 connector to make sure I don't have a short or open somewhere. Can anyone tell me if there is a wire harness connector behind the intake that affects the O2 sensors? I can't see the area or fit my hand in there to check. Maybe I missed reconnecting it?

 

Gold star for you Dave: icon_dance-tap:!

I finally did the compression check (I know, I should have done that first. ). I had no compression in cylinders 6 & 8. The pushrods for the intake valves in cylinders 6 & 8 are not moving. There appears to be something wrong with the new hydraulic lifters in those 2 cylinders.

I wish this was my Chevy so I wouldn't have to take the head off again to get to the lifters.

For the record, I eventually replaced the O2 sensors because they 130,000 miles on them and were throwing codes P0131 & P0152. After I replaced the front O2 sensors, I started getting code P0172.

When I pulled the plugs, cylinders 1,2,3,4,5 were sooty (running rich). Cylinder 7 appeared to be running lean. Cylinders 6 & 8 appeared wet with fuel.

Thanks all for your help. I will update when I actually get the lifter out and get the truck running.

 

There is an alignment tool you can use so that doesn't happen. It's not uncommon for the push rods to not get seated on the lifter.

https://millerspecialtools.service-s...il.aspx?id=766

 

Thanks TNTech. Under the "Current Usage" for that tool, it starts with 2006. Mine is a 2004. It does show body type HB which is what I have. Will this tool work for the 2004?

I am going to pull the intake rocker arm assembly tonight to take a closer look. My fear is that the oil passage in the block is clogged and not sure how I will clean that without taking the entire engine apart again. Do these 2 lifters share the same oil passage? I am also going to have someone crank the engine while I check if oil is squirting through these 2 pushrods.

If the pushrod is not fully seated into the lifter, wouldn't I still see movement as the rod rides up and down on the edge of the lifter?

 

The same tool number for a 2004 Hemi.

 

It is fixed!

I installed both exhaust lifter assemblies and one of the intake assemblies. My brother installed the other one. He inadvertently inserted the pushrods for the intake valves of cylinders 6 & 8 in the wrong hole in the head. He put them in the hole just above the one for the lifter. They felt snug and looked right and I did not notice the mistake.

So I loosened the rocker assembly relocated the pushrods and now the truck is running like new. I can't believe I wasted months on this.

Thanks all for your help.

 

Glad you got it running! Should be good to go now....Back to basics, fuel, compression, spark. Glad you had no damage and didn't have to pull the heads. I do recommend replacing the valve springs, as they will fail on the 2004. The new ones are cheap and are a different design. I rented a custom Hemi spring compression tool from an outfit in FL for $15 and used compressed air at TDC to keep the valves in place. Not too bad a job, you know now how to R&R the rockers. Peace of mind, as a broken exhaust valve will destroy your new engine.
Happy for your success.
Dave

 

Yeah, I didn't see the history of spring problems when I had the heads rebuilt or I would have replaced them. I am going to replace them after I break in the new engine for a few hundred miles.

Do you have info or a picture of the spring compression tool so I can find one in NJ?