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SKU #: BD-1050070 MPN #: 1050070

BD Common Rail Fuel Plug 03-07 5.9L Cummins

$44.95
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Description
A very common failure of the 5.9L Common Rail Cummins is that of the pressure relief valve. These relief valves are a simple spring that is designed to relieve pressure as it exceeds a predetermined pressure, typically around 27,000psi. Unfortunately, as pressure is continually applied to this spring, it fatigues and does not have the ability to maintain even stock pressures. Now, throw pressure boxes and other power adders into the mix that demand higher rail pressure, and this spring further fatigues, causing you to lose valuable rail pressure. This Rail Plug easily installs into the factory rail and eliminates the troublesome pressure relief valve to ensure you're getting the commanded rail pressure of your CP3 all the way to your injectors.

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A very common failure of the 5.9L Common Rail Cummins is that of the pressure relief valve. These relief valves are a simple spring that is designed to relieve pressure as it exceeds a predetermined pressure, typically around 27,000psi. Unfortunately, as pressure is continually applied to this spring, it fatigues and does not have the ability to maintain even stock pressures. Now, throw pressure boxes and other power adders into the mix that demand higher rail pressure, and this spring further fatigues, causing you to lose valuable rail pressure.

This Rail Plug easily installs into the factory rail and eliminates the troublesome pressure relief valve to ensure you're getting the commanded rail pressure of your CP3 all the way to your injectors.

NOT LEGAL FOR SALE OR USE IN CALIFORNIA
Manuals and Guides
Vehicle Fitment
2003-2007 Dodge Ram 5.9L Cummins
WARNING: Cancer & Reproductive Harm - P65Warnings.ca.gov
About BD-Power

BD Diesel is known as one of the originators of diesel performance because theyve been there since the very beginning. Its by no coincidence that theyve been in the industry since 1972 where theyve seen competition come and go over the years. You could consider them a front to back organization in which they design and manufacture products ranging from Super B Turbo Kits and performance injectors for your Cummins to heavy duty transmissions, torque converters, and other transmission components for your Duramax to Positive Air Shutdowns and exhaust brakes for your Powerstroke and everything in between. Quite literally, there are VERY few components that BD does not build for nearly every light duty diesel application.

BD DIESEL PERFORMANCE

Originally founded in 1972 as Valley Fuel Injection that specialized in fuel injection rebuilding and calibrating, BD Diesel gained the most notoriety beginning in 1989 with the release of their first exhaust brake designed for Ram trucks with the acclaimed 12 Valve Cummins engine. BD would later rename Valley Fuel Injection to BD Diesel Truck Service and Performance Center that operates as an extension to BD Diesel Performance. Today, they operate out of a 65,000 square foot facility in Abbotsford, British Columbia and employ over 100 highly skilled individuals. They are constantly pushing the envelope with forward thinking products that not only fill voids in the marketplace, but also take existing products and push them to the next level.

BD DIESEL TRANSMISSION UPGRADES

Transmissions have a singular but ambitious challenge - to transfer all the torque from the diesel engine to the drive wheels. This must be accomplished while maintaining shift quality and minimizing NVH (Noise, Vibration, and Harshness). With stock or OE configurations, this capacity challenge is somewhat less than extraordinary. Comparatively, a high output diesel that develops 2-4 times the original engine torque and keeping stellar driving characteristics at this power level becomes a new feat. Utilizing the latest technology in CAD and FEA simulation, BD can predict and eliminate failures before they happen. The dedicated team of BDs Transmission and Torque Convertor Department are true experts in the development and analysis of the diesel transmission.

BD EXHAUST BRAKES

BD built its reputation on exhaust brakes starting in the early 90's with many casting designs for both engine and remote mount air actuated systems. Rugged cast-iron bodies with an offset stainless steel butterfly build peak efficiency quickly.

BD TURBO UPGRADES

The turbocharger industry is a special industry for BD and remains a key technological asset. When looking at BDs experienced staff, the majority of their key staff members have been developed in or around this technology. BD focuses on the customer's needs, whether it is fast turnaround, state of the art compressor wheels or turbine wheels, they look to deliver on the highest expectations. You can be assured that a BD turbocharger has been hand crafted to the greatest standards. Using precision lathes, milling equipment, honing machines, and inspection CMMs your turbocharger is continuously graded to exceed the OEMs specifications.

BD FUELING UPGRADES

Owing to its heritage as a diesel fuel systems specialist, BD Diesel Truck Service & Performance Center is a factory-certified Bosch, Stanadyne, Delphi and Zexel calibration and repair lab. They are one of a select few injection shops in North America to have Bosch Common Rail parts and an overhaul and testing franchise. BD Diesel rebuilds most all mechanical and electronically-controlled fuel pumps and injectors for diesel engine applications.

BD ELECTRONICS

Throughout the automotive industry, electronic technology has become an integral part of the OEM solution. Whether it is safety, performance, or driving improvements, BD Diesel Performance has developed a strong electronic department to focus strictly on this technology. By focusing on the core needs of the customer, they engineer out the possible product failures and maximize key features to deliver a top to bottom solution. Utilizing state of the art manufacturing equipment, BD maximizes value and minimizes time consuming tasks that inflate costs. Vehicle electronic technology will remain a key technology at BD Diesel Performance.

Video
Product Overview: BD Common Rail Fuel Plug
Running tunes on your rig? Experiencing low fuel rail pressure? Chances are your stock pressure relief valve is no longer doing its job. This is prevalent in tuned or high mileage trucks. Eliminate the issue altogether by installing BD’s Common Rail Plug. Shop BD Common Rail Fuel Plug:

Overall rating: 4.6153846 / 5 from 26 reviews.

AI Generated Review Summary

Summary topics

Review topics: [quality, install, works, buy, pressure, tool].

Review highlights

Reviews

Fuel plug

"Works great"

Terry T. (5/5)

Good product

"Quality, easy to Install,"

Sebastian S. (5/5)

Doesn’t fit. Fits the hole

"Doesn’t fit. Fits the hole in the rail but not sensor, not sure why that would be different or I’m just doing something wrong. No instructions besides torque so shouldn’t be a hard thing to install I wouldn’t think. Can’t use it tho. 03 5. 9 cummins"

Brandon H. (1/5)

Good

"Looks and works as described"

Ehskibba (5/5)

Perfect

"Perfect"

Coe M. (5/5)

Looks good but haven’t installed

"Looks good but haven’t installed yet"

Joel V. (5/5)

Works well would order again

"Works well would order again"

Brett H. (5/5)

Came on time and worked

"Came on time and worked as described"

Dustin M. (5/5)

Works

"Product does what it says it does, plugs the PRV. Be careful you dont damage your fuel rail pressure sensor like i did, it is located right next to the PRV and during removal or install if using wrench instead of socket you can bump in to your fuel rail pressure sensor."

Eva L. (5/5)

Would buy again.

"Works as designed, but be careful with removing the PRV from a performance system. That pressure is going to go somewhere if it can't get out the valve, and it's going to result in blowing apart an injector or six."

Classic C. (3/5)

Q&A

I have a 2003 Dodge Cummins 5.9 I'm having hard start problems I have to hit it with either to get it to start once it runs it runs fine but is that due to the fuel pressure relief valve I want to replace it with the plug but I'm worried about ruining my injectors I have the fast fuel titanium fuel system on it the truck is stock other than that will that plug harm my injectors or could it be another cause why it's hard to start if it runs for a while it'll start but cranks for a little bit if it sits too long I have to start it with either
On a stock truck it is not really an issue to run a plug. In stock form the PRV should never open, but after many years they can loose spring tension and open up earlier. You can try it as a test plug even. Swap it in and see if that takes care of your issue. -Sands
I have a 2003 Dodge Cummins 5.9 I'm having hard start problems I have to hit it with either to get it to start once it runs it runs fine but is that due to the fuel pressure relief valve I want to replace it with the plug but I'm worried about ruining my injectors I have the fast fuel titanium fuel system on it the truck is stock other than that will that plug harm my injectors or could it be another cause why it's hard to start if it runs for a while it'll start but cranks for a little bit if it sits too long I have to start it with either
On a stock truck it is not really an issue to run a plug. In stock form the PRV should never open, but after many years they can loose spring tension and open up earlier. You can try it as a test plug even. Swap it in and see if that takes care of your issue. -Sands
I have read on a few different sites that using a common rail fuel plug can cause fuel system damage. Possibly damage the injector nozzles themselves. Looking over your recipes for horsepower for the 03 to 07 cummins i see this plug listed quite a bit. I have a 2006 2500 5.9 and as far as I know the fuel system is all stock. Right now I have everything listed on your recipe for 400 horsepower except for this fuel plug. I don't drive my truck super hard all the time, and I am not getting any codes. Would I really benefit from this plug if I don't seem to be having any issues? Occasionally I will get a hard start in the mornings and have to turn it over twice to get it to start, or hold the key while it cranks over a little extra before starting. Curious to hear your input. Thank you
If you are not getting any codes and your rail pressure is not dropping there is no reason to plug it. As long as you have something to monitor rail pressure there is no issue running a plug.
I have read on a few different sites that using a common rail fuel plug can cause fuel system damage. Possibly damage the injector nozzles themselves. Looking over your recipes for horsepower for the 03 to 07 cummins i see this plug listed quite a bit. I have a 2006 2500 5.9 and as far as I know the fuel system is all stock. Right now I have everything listed on your recipe for 400 horsepower except for this fuel plug. I don't drive my truck super hard all the time, and I am not getting any codes. Would I really benefit from this plug if I don't seem to be having any issues? Occasionally I will get a hard start in the mornings and have to turn it over twice to get it to start, or hold the key while it cranks over a little extra before starting. Curious to hear your input. Thank you
If you are not getting any codes and your rail pressure is not dropping there is no reason to plug it. As long as you have something to monitor rail pressure there is no issue running a plug.