0445120255
BOSCH 0445120255 Common Rail Injector for Dodge Ram 2500 / 3500 6.7 Cummins ISB
68069384AA, 68005335AA, 68027067AA, R8005335AA, RL005335AA, RL027067AA, RL069384AA, 4983514, 5263307, 5263307NX, 4940589, 4940589RX, 5263307RXF00RJ02130DSLA143P55191600 barProduct Overview
The Bosch 0445120255 is the genuine OEM heavy-duty CRIN2 solenoid common rail injector engineered specifically for the 2007.5–2012 Dodge Ram 2500, 3500, and 4500/5500 Chassis Cab equipped with the 6.7L Cummins ISB Turbo Diesel engine. Operating at system rail pressures up to 1600 bar, this injector features a high-precision DSLA143P5519 nozzle (internal part number 0433175519) combined with a fast-acting F00RJ02130 hydraulic control valve and magnet assembly F00RJ02697. This internal configuration delivers micro-second multi-pilot and post-injection metering to satisfy EPA07, EPA10, and Euro 4/5 emissions while maximizing low-end torque. Crucially, fuel delivery on the Cummins ISB cylinder head is supplied through a side-entry high-pressure fuel connector tube sealed against the injector body via a machined conical seat; proper alignment, seat cleanliness, and exact torque staging are critical to avoiding internal fuel leaks and P0087 low rail pressure trouble codes.
Always replace fuel connector feed tubes alongside injectors on 6.7L Cummins ISB engines. Perform the 3-step torque sequence (15 N·m connector pre-tighten ➔ 8 N·m + 90° hold-down clamp ➔ 50 N·m connector final) and program the individual IMA trim code into the ECU to prevent high-pressure fuel leakage, hard starting, and rough idle.
Vehicle & Engine Fitment
| Vehicle | Engine | Years |
|---|---|---|
| Dodge Ram 2500 6.7 Cummins Turbo Diesel | Cummins ISB / QSB 6.7L (ISDe / Komatsu SAA6D107E) | 2007-2012 |
| Dodge Ram 3500 6.7 Cummins Turbo Diesel | Cummins ISB / QSB 6.7L (ISDe / Komatsu SAA6D107E) | 2007-2012 |
| Ram 4500 / 5500 Chassis Cab 6.7 Cummins | Cummins ISB / QSB 6.7L (ISDe / Komatsu SAA6D107E) | 2008-2012 |
| Cummins ISB 6.7 Industrial / Commercial | Cummins ISB / QSB 6.7L (ISDe / Komatsu SAA6D107E) | 2007-2013 |
Technical Specifications
| Specification | Value |
|---|---|
| SKU | 0445120255 |
| Brand | Dodge / Ram / Cummins / BOSCH |
| Type | Complete Injector Assembly (Bosch Common Rail CRIN2) |
| OE Number | 68069384AA, 4983514, 5263307NX |
| Control ValveCore Spec | |
| Nozzle CodeCore Spec | |
| Internal Nozzle P/NCore Spec | |
| Operating PressureCore Spec | |
| Torque Spec | 35 N·m |
| Hold Down Torque | 8 N·m + 90° |
| Warranty | 12 Months |
| Emission Standard | Euro 4 / Euro 5 / EPA07 / EPA10 |
| Engine Family | Cummins ISB 6.7L Turbo Diesel (24V CRD) |
| Coding Required | Yes (IMA Code) |
| Magnet Assembly | F00RJ02697 |
| Seal Ring Kit | F00RJ02176 |
Installation Tips
Tools needed: 24mm open-end wrench / connector tube nut socket, 8mm and 10mm sockets (valve cover and hold-down clamp), Calibrated torque wrench (5 N·m to 60 N·m range), Torque angle gauge / digital angle meter (for 90° TTY sweep), Injector connector tube puller tool, Brass well cleaning kit & industrial vacuum, Clean fuel line blanking caps, Diagnostic scan tool with Cummins IMA coding function
- Depressurize & Battery Disconnect: Isolate the negative battery cables and ensure common rail fuel pressure reads 0 bar on live scanner data before loosening high-pressure lines.
- Remove Valve Cover & Rocker Assembly: Unbolt the rocker cover and carefully remove the integrated injector harness connector block without straining internal terminal pins.
- Extract Fuel Connector Tubes First: Unscrew the outer 24mm retaining nut on the cylinder head flank, then use a dedicated tube puller to extract the fuel connector feed tube. ALWAYS inspect the tip for galling or deformation.
- Unbolt Hold-Down Clamp: Remove the injector hold-down clamp bolt. Note that this bolt is a Torque-to-Yield (TTY) fastener and must be replaced with a new bolt upon reassembly.
- Withdraw Injector Body: Lift the 0445120255 injector straight out of the well. If seized from carbon ingress, use a vertical mechanical puller; never pry against the cylinder head or twist the body.
- Inspect & Clean Bore: Verify the old copper crush washer did not stick in the cylinder head bore. Ream and vacuum the bottom seat to remove all carbon soot and debris.
- Fit New Washer & Lube Body: Place a fresh OEM 1.5mm copper washer onto the nozzle using clean high-temp grease, and apply a light film of ceramic paste to the injector body barrel (keep nozzle tip completely dry).
- Insert Injector: Slide injector into the bore ensuring the side fuel inlet orifice is perfectly aligned with the transverse connector tube passage.
- Step 1 - Snug Connector Tube: Insert a NEW fuel connector tube until it bottoms out against the injector body spherical pocket. Finger-tighten the retaining nut, then torque gently to 15 N·m (11 ft-lbs) to center and align the assembly.
- Step 2 - Torque Injector Hold-Down Clamp: Tighten the hold-down clamp bolt to 8 N·m (71 in-lbs), then apply a further 90-degree torque-to-yield rotation using an angle gauge.
- Step 3 - Final Torque Connector Tube: Complete the torque sequence by tightening the 24mm connector tube retaining nut to 50 N·m (37 ft-lbs). Do not exceed this spec to prevent seat crushing.
- Reassemble & Code ECU: Reinstall rocker bridges, valve cover, and high-pressure rail jumpers (torque jumpers to 35 N·m). Input the alphanumeric IMA trim code printed on the injector body into the engine ECM, bleed air from the low-pressure supply, and verify no leakage under 1600 bar operating pressure.
- NEVER REUSE CONNECTOR TUBES: The connector tube nose features a deformable crush collar designed for single-time seating. Reusing old tubes is the #1 cause of internal high-pressure fuel leaks and P0087 fault codes.
- STRICT 3-STEP TORQUE ORDER: Reversing the torque order (e.g., clamping the injector tight before inserting the tube) misaligns the spherical seat, leading to fuel spraying into the crankcase oil.
- CLEANLINESS IS PARAMOUNT: Even a 5-micron soot particle trapped on the connector tube spherical face will prevent sealing against 1600 bar diesel pressure.
- REPLACE TTY HOLD-DOWN BOLTS: The injector clamp bolt stretches under the 8 N·m + 90° specification and will lose clamping preload if reused.
Frequently Asked Questions
What is the difference between injector 0445120255 and earlier 5.9L injector 0445120238?
While both injectors are CRIN2 architecture sharing the same control valve (F00RJ02130) and 1600 bar rail pressure rating, 0445120255 features a revised DSLA143P5519 nozzle with spray pattern, flow rate, and hydraulic response calibrated for the larger displacement 6.7L combustion bowl and EPA07/EPA10 emissions. The 5.9L unit (0445120238) uses nozzle DSLA124P5500. They are not interchangeable; mixing them will cause severe ECU trim faults, rough running, and DPF regeneration failure.
Why does my 6.7 Cummins exhibit long cranking and P0087 after installing new injectors?
The most frequent cause of long cranking (crank time > 4-5 seconds) and code P0087 (Fuel Rail Pressure Too Low During Cranking) following an injector swap is fuel connector feed tube misalignment or under-torquing. If the connector tube was not torqued in the strict 3-step sequence (15 N·m pre-tighten ➔ 8 N·m + 90° clamp ➔ 50 N·m final), high-pressure fuel leaks past the spherical seat directly into the cylinder head drain gallery, preventing the rail from achieving the required 250-300 bar cranking threshold.
Can I reuse the fuel connector tubes when replacing 0445120255 injectors?
No. Cummins and Bosch factory technical service bulletins strictly mandate replacing the fuel connector tubes (Cummins part number 4929864 / 4934330) whenever injectors are removed. The leading spherical tip and crush edge undergo plastic deformation during initial torquing to conform to the injector port. A reused tube will almost invariably weep high-pressure fuel, causing hard starts or fuel-in-oil dilution.
Does Bosch 0445120255 require IMA coding in the Dodge Ram ECM?
Yes. Each 0445120255 injector is individually flow-bench tested at the factory and laser-etched with a unique alphanumeric IMA calibration code on the solenoid cap. This code must be programmed into the engine control module using a diagnostic scanner (such as WiTech, Cummins INSITE, Autel MaxiSys, or Snap-on) so the ECM can compensate for micro-tolerances across pilot, main, and post-injection quantities.
What thickness copper washer should be used on the 6.7L Cummins ISB?
The standard factory copper sealing washer for 0445120255 is 1.5mm thickness (Bosch seal ring kit F00RJ02176). Using an incorrect thickness changes the injector protrusion depth into the piston bowl, altering the spray cone impingement angle, increasing particulate emissions, and potentially causing hot spots on the piston rim.
Diagnostic Trouble Codes & Fault Protocols
Common diagnostic trouble codes (DTCs) triggered when this common rail injector experiences wear, circuit faults, or calibration drift:
Fuel Rail / System Pressure Too Low
Excessive internal backleak from worn control valve seats drops common rail pressure below target under engine load.
Injector Circuit Malfunction / Open Circuit
Solenoid coil resistance drift (0.2-0.5 Ω) or piezo stack degradation triggers driver stage shutdown on affected cylinders.
Cylinder Misfire & Balancing Deviation
Carbon-clogged nozzle spray holes or missing IMA calibration causes uneven cylinder contribution. Recode ECM and verify washer seating.
Fuel Rail / System Pressure Too High
Spill line backpressure or stuck metering valve prevents rail depressurization, creating overpressure risks under load.
Cross-Reference & Compatibility
Sister parts, same-platform variants, and known incompatibilities.
Technical Diagnostic & Service Protocols
Authoritative field procedures, diagnostic testing thresholds, and service SOPs for this assembly.