All the cylinders spark tested the same, seem ok. All the spark plugs look the same so no suspect cylinders, at least in the first 100 miles. The cylinders were compression tested cold, no oil and are as follows:
Cyl # PSI
1 149
2 160
3 180
4 148
5 143
6 150
7 140
8 143
9 150
10 151

Cylinders 2 and 3 have me puzzled. No smoking gun though except maybe this new development. I sounds like its time to pull the valve covers.

 

Well pulled the passenger side valve cover. Of the 6 pushrods I've pulled 5 were slightly bent. Just enough that you can see it and they don't roll smooth. Going to measure for correct length tomorrow.

 

So I need to buy longer push rods. My only concern is how much lifter preload. I was thinking .050-.060"? Any ones have input? Keep in mind these are the same lifters as the 5.9 v8.

 

My machinist suggested .060, that is how I ordered the pushrods. Smith Brothers had them.
Which cylinders are misfiring when the trouble starts?

 

Hard to tell. I'm suspecting it is cylinder #3 which was 35 above the average on my compression test. I ordered rods that will be .060" pre load based of off my measurements. Right now the whole passenger side has no preload, with 5 of the 6 I've pulled so far being slightly bent. I had a what was I thinking moment. Like really stock rods with out measuring on a regrind? I can't believe I did that. I hope this is my issue. I had some noise developing under the passenger side valve cover and maybe the drivers, that's when it hit me.

 

Ok so I learned a few things:

1. I need to re-measure my push rod length, I was too short.
2. The push rods that were in the truck were already ~.050" longer than stock.
3. The high compression on those 2 cylinders represented the old push rods were just barely too short (not all the push rods that came out were the same length, so so much they were easily seen with the naked eye).

So at least I know I have a push rod problem now. Hopefully I can get them measured to the correct length next time. Now I am stuck with new pushrods that are too short but I a valuable lesson learned.

 

That's how I learned when I was throwing money away I learned QUICKLY how not to do that

 

So I got another set of push rods. They're in but I haven't gotten the truck fully together. Didn't stop me from doing a quick compression check on 2 cylinders. Interesting results:
cylinder #2 160psi-->186psi
cylinder #4 148psi-->185psi

Both cylinder picked up quite a bit. Gives me hope I finally found my problem.

 

Well put reman injectors in, have an intermittent short on one that blows the engine control fuse 1 for the ASD. However when I check the injectors are all correct resistance. So waiting on another set.

 

.Well I'm at my wits end (and financial end) with this truck. Reman injectors helped but not gone. Interestingly I did get 2 codes upon start up. P0113 Intake temp voltage to high, and P0123 TPS voltage to high. The TPS is new the IAT is not. However I cleared and they didn't come back. I did notice with the scan tool that once it hits closed loop the idle quality instantly decreases and while I watched the scan tool I noticed the ignition timing went from varying 3 degrees open loop to varying 12 degrees closed loop.