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Discussion Starter · #1 ·
Hey all - as the title says my truck (04.5 5.9 HO) will start rough when it’s been sitting for a few hours. It makes a popping noise out of the exhaust, sounds kind of like a misfire, and blows a cloud of blue smoke and hazes for about 30 seconds to a minute. I can’t tell if I have a leaking injector or my turbo is going bad or what - the reason I even suspect the turbo is because at freeway speeds from 55-60 if I lean into the pedal with a tune on (I run a Edge Juice w/Attitude) on tunes 3-5, the truck starts to shake/sputter rapidly like the motor is cutting in and out. It’s starting to become evident even without a tune. Not really sure what to think but I’m pretty sure it’s on the fuel delivery end of things. If it helps I can get a video of startup when I leave today, and can try to get the shaking on camera but I’m not sure how that will pick up. If anyone has any suggestions let me know. Thanks!
 

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When was the last time fuel and air filters were changed? Also is your fuel pump on the back of the filter housing or in tank? Fuel pump could be going out if it's the original and on the fuel canister.
Larry
 

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That sounds like a bad injector to me. From your description, the popping sound might be extra fuel that has leaked out of an injector and is sitting on top of a piston. Typical of blue smoke and haze I think too. You should check there before it causes more damage.
 
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Discussion Starter · #4 ·
When was the last time fuel and air filters were changed? Also is your fuel pump on the back of the filter housing or in tank? Fuel pump could be going out if it's the original and on the fuel canister.
Larry
All great questions that I should have thought to clarify on! It has an in tank lift pump since it’s the 04.5, which was replaced last winter and the truck has barely seen 10,000 miles since then. New air filter and fuel filter about 1500 miles ago. Oil was just changed. Last time I checked the turbo I had a tiny bit of shaft play (maybe a one or two ten thousandths of an inch) but that was it. The only thing I haven’t checked is a filter I’ve heard of that’s supposed to be on or underneath the valve cover (PCV filter? Can’t remember off the top of my head) and the injectors. I’ve checked for all boost leaks and have none. Like jhbowhunter suggested the more I think about it the more I have to guess injector since I have good rail pressure and a new pump but it gets worse when I try to put more fuel to the motor. Any thoughts on how to check this out without bringing it to someone or am I pretty well out of luck as far as checking on it for free?
 

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Hate to tell you ,no such thing as 04.5 HO.
03-04 is HO which is 305hp ,555ft/lb motor different pistons,injectors, turbo
So do you have the right tuner/ parts?

Guess Like jhbowhunter stated your edge increased rail pressure probally wore/damaged your injectors.
Can get correct info on your truck and how diagnose is available in Newbies Guide on here

Newbies guide to your new to you truck
 

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Discussion Starter · #6 ·
Hate to tell you ,no such thing as 04.5 HO.
03-04 is HO which is 305hp ,555ft/lb motor different pistons,injectors, turbo
So do you have the right tuner/ parts?

Guess Like jhbowhunter stated your edge increased rail pressure probally wore/damaged your injectors.
Can get correct info on your truck and how diagnose is available in Newbies Guide on here

Newbies guide to your new to you truck
It is an 04.5 for sure - build date and location of the overflow bottle/how the fan shroud is mounted indicate that. I have a tuner for an 04.5 to 05 because of this. The reason I say HO is because the valve cover sticker indicates 325 hp. I thought this meant it was the HO but I may have confused myself.
 

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Nah engne wise 600 series, same as 05 to end of production of 5.9l in Dodge trucks

2003 S.O. Federal Emissions: 250HP/460lb.ft. Available with NV4500 or 47RE
2003 S.O. Calif. Emissions: 235HP/460lb.ft. Available with NV4500 or 47RE
2003 H.O. Federal Emissions: 305HP/555lb.ft. Only available with NV5600
2003.5 The 47RE was replaced by the 48RE automatic transmission and available with the H.O.
2004 S.O. Calif. Emissions: 235HP/460lb.ft. Available with NV4500 or 48RE
2004 H.O. Federal Emissions: 305HP/555lb.ft. Available with either NV5600 or 48RE

2004.5 (50 state legal) 325HP/600lb.ft. Available with either the 48RE or NV5600
2005 (50 state legal) 325HP/610lb.ft. Available with either the 48RE or NV5600
2005.5 The NV5600 replaced with the G56 6spd manual gearbox.
 

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Discussion Starter · #8 ·
Nah engne wise 600 series, same as 05 to end of production of 5.9l in Dodge trucks

2003 S.O. Federal Emissions: 250HP/460lb.ft. Available with NV4500 or 47RE
2003 S.O. Calif. Emissions: 235HP/460lb.ft. Available with NV4500 or 47RE
2003 H.O. Federal Emissions: 305HP/555lb.ft. Only available with NV5600
2003.5 The 47RE was replaced by the 48RE automatic transmission and available with the H.O.
2004 S.O. Calif. Emissions: 235HP/460lb.ft. Available with NV4500 or 48RE
2004 H.O. Federal Emissions: 305HP/555lb.ft. Available with either NV5600 or 48RE

2004.5 (50 state legal) 325HP/600lb.ft. Available with either the 48RE or NV5600
2005 (50 state legal) 325HP/610lb.ft. Available with either the 48RE or NV5600
2005.5 The NV5600 replaced with the G56 6spd manual gearbox.
I gotcha - good to know. I must have confused myself when looking online. LOL. Nope that should mean I have the right tuner. The truck has 208,000 miles on it so I wouldn’t be surprised if the injectors are just worn out either. What will I have to do in order to investigate further?
 

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The only way to know for sure is measure return of fuel injectors.
Gonna need test fittings to measure return
Genos has a kit and info '03-'07, 5.9L Dodge Diesel HPCR Fuel Pump Return Flow Test Kit (genosgarage.com)
If you need injectors do yourself a favor get NEW Bosch injectors or BBI's if looking for more HP.

In your situation, that misfire/blue smoke worries me, I would check compression, IIRC 350 psi + minimum
 
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