Dodge Ram Diesel 5.9L Fuel Injector 0 986 435 505, R5135790AD Year 2004.5 - 2007 325HP
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This is a remanufactured factory fuel injector. These are the highest quality in the industry.
The Bosch Common rail system has been tested and proven. The life of the fuel system depends on proper maintance. The system workS under very high pressure 23,000 PSI. Any contamination in the fuel system becomes very abrasive. The contamination will damage the fuel injector and high pressure pump. Replacing the CP3 pump can help avoid this.
We strongly reccommend that you also replace the fuel filter and fuel supply tubes when replacing these injectors!!!
ATTENTION!!! This is the LATE MODEL version of the R5135790AD fuel injector!!!
The Cummins ISB 5.9L Engine produces 325HP. This information is noted on the side of valve cover toward the front driver side. This engine was produced from 2004 1/2 to 2007. The injector has 5 holes. Please note if your truck is a 2004 please make sure you have the correct injector. If you have a 305hp engine you will need the EARLY MODEL FUEL INJECTOR.
Alternate Part Numbers:
This Fuel Injector is made for:
You will need special high-pressure connector removal tool #9015 to perform this procedure.
INJECTOR REMOVAL STEPS:
Six individual, solenoid actuated high-pressure fuel injectors (7) are used. The injectors are vertically mounted into a bored hole in the top of the cylinder head. This bored hole is located between the intake/exhaust valves. High-pressure connectors, mounted into the side of the cylinder head, connect each fuel injector to each high-pressure fuel line.
Step One: Disconnect both negative battery cables from both batteries. Cover and isolate ends of cables.
Step Two: Remove breather assembly.
Step Three: Remove valve cover. Refer to Engines for procedures.
Step Four: Remove all 12 fuel injector wire harness nuts (1) securing integrated wiring harness to all 6 fuel injectors.
Step Five: An integrated fuel injector wire harness /valve cover gasket (2) is used. After all 12 nuts (1) have been removed, remove this integrated gasket. Before removing gasket, disconnect engine wiring harness at both electrical connectors (3).
Step Six: Remove necessary high pressure fuel line connecting necessary fuel injector rail to high pressure connector. Refer to Fuel Line Removal for procedures.
Step Seven: A connector retainer (nut) is used on each connector tube. Remove this nut(s) by unthreading from cylinder head.
Step Eight: Using special high-pressure connector removal tool #9015 (2) remove necessary high-pressure connector(s) from cylinder head. Tool #9015 threads onto connector tube. Use tool to pry connector tube(s) from cylinder head.
Step Nine: Remove 2 fuel injector hold-down clamp bolts (1) at each injector being removed.
Step Ten: Remove necessary exhaust rocker arm assembly(s).
Step Eleven: USING TOOL #9010:
Step Twelve: Remove and discard injector sealing washer (2). This washer should be located on tip of injector, or may have remained in the injector bore.
Step One: Inspect fuel injector:
Step Two: Thoroughly clean fuel injector cylinder head bore. Blow out bore hole with compressed air.
Step Three: The bottom of fuel injector is sealed to cylinder head bore with a copper sealing washer (shim) (1) of a certain thickness. A new shim (1) with correct thickness must always be re-installed after removing injector. Measure thickness of injector shim (1). Shim Thickness: 1.5 mm (0.06 inchess)
Step Four: Install new shim (1) (washer) to bottom of injector. Apply light coating of clean engine oil to washer. This will keep washer in place during installation.
Step Five: Install new O-ring to fuel injector. Apply small amount of clean engine oil to O-ring.
Step Six: Install injector into cylinder head with male (highpressure) connector port facing the intake manifold. Push down on fuel injector mounting flange to engage O-ring and seat injector.
Step Seven: Tightening Sequence:
Install fuel injector holdown clamp (mounting flange) bolts. Do a preliminary tightening of these bolts to 5 Nm (44 in. lbs.) torque. This preliminary tightening insures the fuel injector is seated and centered.
Step Eight: Connect injector solenoid wires and nuts to top of injectors. Tighten connector nuts to 1.25 Nm (11 in. lbs.) torque. Be very careful not to overtighten these nuts as damage to fuel injector will occur.
Step Nine: Install exhaust rocker arm assembly. Refer to the Diesel Engine section.
Step Ten: Set exhaust valve lash. Refer to the Diesel Engine section.
Step Eleven: Install high pressure fuel line. Refer to Torque Specifications. Be sure to use a secondary back-up wrench on the connector nut (fitting) while torquing fuel line fitting. Refer to Fuel Line Installation for additional information.
Step Twelve: Install valve cover. Refer to the Diesel Engine section.
Step Thirteen: Install breather assembly.
Step Fourteen: Connect negative battery cables to both batteries.