0445120020
BOSCH 0445120020 Common Rail Injector for Renault Kerax, Premium & Dongfeng Tianlong dCi 11
5010477874, 5010550956, 5001866647, 501550956, D5010477874, 503135250F00RJ00399DLLA150P10761600 barProduct Overview
The Bosch 0445120020 is a heavy-duty CRIN1-14/16 commercial vehicle common rail diesel fuel injector engineered for Renault Trucks Kerax and Premium models powered by the 11.1L dCi 11 engine family (including dCi 11C and dCi 11E, rated at 266 kW / 370 HP and 303 kW / 420 HP), as well as Dongfeng Tianlong Kinland heavy commercial transports. Operating at injection pressures up to 1600 bar, this hydraulic assembly relies on control valve F00RJ00399, hole-type nozzle 0433171699 (stamped DLLA150P1076), and magnet assembly F00RJ02697 to ensure precise multi-injection metering meeting Euro 3 commercial emission standards. High-mileage field failure symptoms include excessive dynamic fuel backleakage into the return rail, hot-start refusal, unburned exhaust smoke under heavy load, and sudden engine derate under highway hauling conditions.
CRITICAL FEED TUBE SEQUENCE: Never tighten the hold-down clamp before seating the high-pressure connector tube. Pre-torque the connector tube retaining nut to 15 N·m first to align the spherical sealing interface with the injector inlet port, torque the hold-down clamp bolt to 26-30 N·m, and finally torque the connector tube to 50-55 N·m to prevent internal high-pressure fuel leakage into the cylinder head and DTC P0087.
Vehicle & Engine Fitment
| Vehicle | Engine | Years |
|---|---|---|
| Renault Premium Distribution / Route / Lander 370 / 420 | Renault / Dongfeng dCi 11 (11.1L Common Rail) | 2000-2006 |
| Renault Kerax 370 / 420 Heavy Construction Truck | Renault / Dongfeng dCi 11 (11.1L Common Rail) | 2001-2006 |
| Dongfeng Tianlong Kinland DFL4251 Heavy Commercial Truck | Renault / Dongfeng dCi 11 (11.1L Common Rail) | 2006-2016 |
| Iveco EuroStar / EuroTech Heavy Commercial Truck | Renault / Dongfeng dCi 11 (11.1L Common Rail) | 2001-2006 |
Technical Specifications
| Specification | Value |
|---|---|
| Fuel System | Bosch Common Rail (CRIN1-14/16) |
| Peak Pressure | 1600 bar |
| Control ValveCore Spec | |
| Nozzle CodeCore Spec | |
| Nozzle Part NumberCore Spec | |
| Magnet Assembly | F00RJ02697 |
| Seal Ring Kit | F00RJ02176 |
| Connector Tube Pre-Torque | 15 N·m |
| Hold-down Clamp Torque | 26-30 N·m📐 Torque & Angle Wizard → |
| Connector Tube Final Torque | 50-55 N·m |
| High Pressure Line Torque | 30-35 N·m |
| Coding Standard | Coding Not Required (CRIN1 Generation) |
| Operating PressureCore Spec |
Installation Tips
Tools needed: Calibrated torque wrench and line crowfoot tool, Brass injector bore seat brush kit and industrial vacuum extraction unit, Dedicated electronic diagnostic tool for IMA/injector coding
- Thoroughly ream and clean the cylinder head injector well down to bare metal using a specialized brass seat brush; blow out all carbon deposits and verify that the copper seating surface is completely clean and smooth.
- Fit a brand-new genuine copper sealing washer of correct thickness (standard 1.5mm) onto the nozzle tip, and lubricate the viton O-ring on the injector body using clean engine oil.
- Lower the 0445120020 injector assembly straight into the cylinder head bore, aligning the lateral high-pressure fuel inlet socket with the transverse cylinder head connector tube port, and secure the clamp bolt finger-tight.
- Insert the high-pressure connector tube (feed tube) through the cylinder head bore, and torque the connector tube retaining nut to the preliminary alignment specification of 15 N·m.
- Torque the injector hold-down clamp bolt to its final torque of 26-30 N·m to securely crush and seat the copper sealing washer against the cylinder head seat.
- Finalize torque on the high-pressure connector tube retaining nut to 50-55 N·m to establish an airtight metal-to-metal spherical seal.
- Install the high-pressure fuel rail line using the 2-wrench counter-hold method, torque the line nut to 30-35 N·m, attach the electrical solenoid harness, and prime the low-pressure fuel supply circuit before initial engine start.
- High-Pressure Feed Tube Alignment Risk: Tightening the hold-down clamp bolt to full torque before seating the feed tube will misalign the spherical sealing joint. This misalignment creates high-pressure internal fuel leakage into the valvetrain, leading to extended cranking, power loss, and fault code P0087. Always maintain the 15 N·m -> 26-30 N·m -> 50-55 N·m torque progression.
- Inspect Feed Tube Sealing Tip: Whenever replacing injector 0445120020, inspect the brass/steel spherical tip of the high-pressure connector tube. Any edge erosion, scratching, or flattening necessitates replacing the connector tube assembly immediately; reusing damaged tubes causes immediate rail pressure loss.
- 2-Wrench Line Torquing Mandate: When tightening the high-pressure fuel rail line to 30-35 N·m, always counter-hold the connector tube retaining nut with a second open-ended wrench. Unopposed torque can twist the connector tube or crack the injector body fuel inlet socket.
Frequently Asked Questions
What symptoms indicate a failing Bosch 0445120020 injector on Renault dCi 11 engines?
Common failure symptoms include hard starting or extended cranking when warm due to excessive dynamic backleakage past control valve F00RJ00399, dense black exhaust smoke under acceleration caused by worn nozzle DLLA150P1076 orifices, engine knocking under load, and diagnostic trouble code P0087 (Fuel Rail Pressure Too Low).
Is ECU coding required after installing injector 0445120020?
No. The Bosch 0445120020 is an early first-generation commercial common rail injector (CRIN1). Unlike later CRIN2 and CRIN3 systems, it does not utilize IMA/IQA calibration coding; the engine ECU regulates cylinder balance automatically via closed-loop crankshaft speed monitoring.
What are the primary OE cross-reference numbers for 0445120020?
Primary OE part numbers include Renault Trucks 5010477874, 5010550956, 5001866647, and 501550956, Dongfeng D5010477874, and Iveco 503135250. The official Bosch remanufactured exchange part number is 0986435523.
What dynamic backleak rate is acceptable during bench testing?
At normal operating temperature under full load (1600 bar), maximum permissible return leakage should not exceed 45 ml/min per injector. Dynamic backleakage exceeding 50 ml/min confirms internal seat wear in control valve F00RJ00399, causing fuel rail pressure drops and hot-restart refusal.
What is the correct coil resistance for solenoid testing?
Using a calibrated digital multimeter at 20°C ambient temperature, measurement across the two solenoid pins must indicate 0.25 to 0.50 Ohms. Resistance below 0.20 Ohms indicates shorted internal windings, while resistance above 0.60 Ohms indicates degraded terminal bonding, either of which triggers solenoid circuit DTCs P0201-P0206.
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.