I've recently purchased a bone stock 2007 5.9 with a 48 re. Bought it with coolant in oil and slipping transmission. I've had multiple vp trucks with nv4500's and 47re's and have done alot of performance mods on them. The commonrail is a new thing to me and I'm looking for suggestions on how to go about building it. A freeze plug popped out in the head so the oil was completely full of coolant. The engine is currently at a machine shop getting re done. They are going to drill and tap freeze plug holes, put oversize valve seats, and oring the head. I just told them to hone block and resurface it for now. I have 103lb valve springs, oversize pushrods, 165 gph fass, fuel sump, 5 inch exhaust, already have a efi live autocal so will probably be using it (who should I get tunes from?), and arp head studs for it now. I'm planning on buying a used compound setup for it that is a s366 over s480 (still open to other options though). Also will be putting a cam in, I ran a stage 3 colt cam in a vp truck but thinking about doing a hamilton this time. So with that what size injectors should I do? Should put 03-04 pistons in it? Dual cp3 or large single? Not really on a specific budget but also not going at it like the sky is the limit. Will probably try to source mostly used parts. What kit should I go with on the 48re? I know there is alot of different threads out there talking about this, I just wanted to start a new one to see different options and if any new stuff is out there. I am not clueless about this stuff and do all my mechanic work (have a p-pump 24 valve 2.5 truck), I am just not familiar with making power with the common rail platform. I got a good deal on the truck and plan on keeping it for a long time. So since its getting a complete rebuild I just want to make sure I go about it the right way. Thanks for any suggestions!

 

I'd suggest something around 100-150 hp for your turbo setup, especially with the s366/s480 compounds. You could go with 5x.014 or 5x.018 injectors depending on your desired power level. As for pistons, 03-04 pistons would be a good choice if you want to stay with stock reliability, but forged would be better for pushing higher power. For the 48RE, consider a SunCoast or ATS kit both are reliable for heavy-duty builds. Dual CP3 is nice for supporting big power, but a large single can handle it if you’re not pushing crazy numbers. As for tuning, EFI Live tunes from Dan at Triple Dog or a custom tuner with experience in common rail trucks would be a good choice.

 

First off, for injectors, I’d go with something around 50-100% over stock, depending on how much you want to push it. Since you're planning on running compounds (S366 over S480), you'll definitely need injectors that can keep up with the fuel demands. I’d recommend something like 100HP+ to match the turbo setup, but don’t go too big unless you’re planning on some crazy fueling setup. You don’t want to overfuel and lose drivability.