1-866-798-6940

BOSTECH #DE801

This is a remanufactured factory fuel injector.  These are the highest quality in the industry.   

We stand behind this product with a 12 month unlimited mile parts and labor warranty.  You can buy the same thing from a dealer but they will not warrant the parts labor unless they install the part themselves.  We back it up with our parts and labor. 

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:

• Bosch #0 445 120 114 
• Bosch #0 445 120 208 
• Bosch reman #0 986 435 505 
• Chrysler #R5135790AD 
• Chrysler #5135790AD  

This Fuel Injector is made for:

• 2005 Dodge Ram Diesel 2500
• 2006 Dodge Ram Diesel 2500
• 2007 Dodge Ram Diesel 2500
• 2004 Dodge Ram Diesel 3500
• 2005 Dodge Ram Diesel 3500
• 2006 Dodge Ram Diesel 3500
• 2007 Dodge Ram Diesel 3500

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:

• a. Special Tool #9010 is equipped with 2 clamshell clamps, a sliding retainer sleeve to retain the clamshell clamps, a 2-piece mounting stud, and a pivoting handle. Do not attempt to remove the fuel injector with any other device. Damage to injector will occur.
• The rocker housing is bolted to the top of cylinder head. The mounting stud from tool #9010 was meant to temporarily replace a rocker housing mounting bolt. Remove the necessary rocker housing mounting bolt. These mounting bolts are located at the center of each of the 3 rocker housing support bridges.
• Install and tighten 2-piece mounting stud to rocker housing. If removing the #6 fuel injector, separate the 2-piece mounting stud. Install lower half of mounting stud to center of rocker housing bridge. Install upper half of mounting stud to lower half.
• Position tool handle to mounting stud and install handle nut. Leave handle nut loose to allow a pivoting action.
• Position lower part of clamshell halves to sides of fuel injector (wider shoulder to bottom). The upper part of clamshell halves should also be positioned into machined shoulder on the handles pivoting head.
• Slide the retainer sleeve over pivoting handle head to lock clamshell halves together.
• Be sure handle pivot nut is loose.
• Depress handle downward to remove fuel injector straight up from cylinder head bore.

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.

• After tightening, relieve bolt torque, but leave both bolts threaded in place.
• Install high-pressure connector and retaining nut. Do a preliminary tightening to 15 Nm (11 ft. lbs.) torque.
• Alternately tighten injector holdown bolts to 10 Nm (89 in. lbs.) torque.
• Do a final tightening of the high-pressure connector and retaining nut. Tighten to 50 Nm (37 ft. lbs.) torque.

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.