FuelPartsDB · WORKSHOP TECHNICAL SERVICE

DOC REF: SOP-CR-INJ-01

WORKSHOP INSTALLATION JOB SHEET & SOP

BOSCH 0445120027BOSCH 0445120027 Common Rail Injector for Hitachi ZX200-3 ZX240-3 Isuzu 4HK1 6HK1 5.2L 7.8L · Euro 334

Technician / Installer:

Date / Odometer:

Vehicle Reg / VIN:

Quality Sign-off:

CRITICAL INSTALLATION SPECIFICATIONS & TORQUES

Torques (Hold-down):26-30 N·m

Torques (Tightening):30-35 N·m

Copper washer:Renew the sealing washer on every installation. 1.50 mm standard; step up to 1.70 mm after light seat reaming, 2.00 mm after heavy seat refinishing.

IMA / ECU coding:Not required for this assembly

MANDATORY INSTALLATION CHECKLIST

[ ]Bore cleaned to bare metal using nylon/brass reaming brush & vacuumed (zero debris / no steel wire)
[ ]New copper sealing washer fitted with correct thickness (do not reuse old washer)
[ ]High-temperature ceramic paste applied to injector body shaft (never coat the nozzle tip)
[ ]Hold-down clamp bolt tightened in stage torque/angle sequence as specified
[ ]Fuel rail high-pressure line union torqued without tension or cross-threading
[ ]IMA / QR calibration code entered into diagnostic tool (Lexia/KTS/VCDS) for cylinder balancing
[ ]Low-pressure air bleed performed, engine idling leak-off test verified leak-free

BOSCH

0445120027

View Specs

SolenoidBosch Common Rail (CRIN2-16)Euro 334

BOSCH 0445120027 Common Rail Injector for Hitachi ZX200-3 ZX240-3 Isuzu 4HK1 6HK1 5.2L 7.8L

Reference data for Bosch 0445120027 common rail injector · OEM 8-97603415-4, 8-97603415-0, 8-97603415-1, 8-97603415-2, 8-97603415-3, 8-97603415-5, 8-97603415-6, 8-97603415-7, 8-97603415-8, 4652265, J6600, 87310574 · Application Isuzu 4HK1 (5.2L) & 6HK1 (7.8L) Electronic Common Rail

Engine Platform:Isuzu 4HK1 (5.2L) & 6HK1 (7.8L) Electronic Common Rail →

OE REFERENCE

8-97603415-4, 8-97603415-0, 8-97603415-1, 8-97603415-2, 8-97603415-3, 8-97603415-5, 8-97603415-6, 8-97603415-7, 8-97603415-8, 4652265, J6600, 87310574

CONTROL VALVEF00RJ01159

NOZZLEDLLA158P1385

RAIL PRESSURE1600 bar

EMISSIONTier 3 / Stage IIIA / Euro 3 / Euro 4

WARRANTY12 Months

Compatible Injectors

OEM Ref

OE Nozzle

Vehicle & Engine Fitment

Vehicle	Engine	Years
Hitachi Zaxis ZX200-3 / ZX200LC-3 Crawler Excavator	Isuzu 4HK1 (5.2L) & 6HK1 (7.8L) Electronic Common Rail	2006-2014
Hitachi Zaxis ZX240-3 / ZX250-3 Heavy Excavator	Isuzu 4HK1 (5.2L) & 6HK1 (7.8L) Electronic Common Rail	2006-2015
Hitachi Zaxis ZX270-3 / ZX330-3 / ZX350-3 Hydraulic Excavator	Isuzu 4HK1 (5.2L) & 6HK1 (7.8L) Electronic Common Rail	2006-2015
JCB JS200 / JS210 / JS220 / JS240 Heavy Tracked Excavator	Isuzu 4HK1 (5.2L) & 6HK1 (7.8L) Electronic Common Rail	2007-2016
Case CX210B / CX240B Hydraulic Crawler Excavator	Isuzu 4HK1 (5.2L) & 6HK1 (7.8L) Electronic Common Rail	2007-2015

Technical Specifications

Specification	Value
Fuel System	Bosch Common Rail (CRIN2-16)
Peak Pressure	1600 bar
Control ValveCore Spec	🔗 Shared Valve (2 assemblies):0445120044
Nozzle CodeCore Spec
Nozzle Part NumberCore Spec
Magnet Assembly	F00RJ02701
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 (CRIN2 Generation)
Operating PressureCore Spec

Diagnostic Trouble Codes & Fault Protocols

Common diagnostic trouble codes (DTCs) triggered when this common rail injector experiences wear, circuit faults, or calibration drift:

P0087Critical

Fuel Rail / System Pressure Too Low

Excessive internal backleak from worn control valve seats drops common rail pressure below target under engine load.

P0087 Guide →🧪 Backleak Calculator

P0201 - P0208High

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.

P0201 Circuit Guide →

P0300 / P0301+High

Cylinder Misfire & Balancing Deviation

Carbon-clogged nozzle spray holes or missing IMA calibration causes uneven cylinder contribution. Recode ECM and verify washer seating.

P0300 Misfire Protocol →💻 IMA Coding Tool 📐 Washer Thickness

P0088High

Fuel Rail / System Pressure Too High

Spill line backpressure or stuck metering valve prevents rail depressurization, creating overpressure risks under load.

P0088 Guide →📊 Rail Pressure Converter

Browse all 61 Diesel Diagnostic Trouble Codes in our Workshop Hub ->

WORKSHOP PROTOCOLS

Technical Diagnostic & Service Protocols

Authoritative field procedures, diagnostic testing thresholds, and service SOPs for this assembly.

Workshop Diagnostic Protocol

Common Rail Injector Back-Leak Testing Guide

Common rail injector backleak test protocol. Graduated cylinder setup, warm idle & cranking limits in mL/min, control valve wear & P0087 diagnosis.

Read Technical Protocol

ECU Calibration Protocol

Bosch IMA Injector Coding & Location Guide

Bosch common rail injector IMA coding guide. Locate laser-etched 6-9 digit codes on body, ECU OBD2 adaptation steps & test bench calibration facts.

Read Technical Protocol

COMMON RAIL DIESEL WORKSHOP SOP

Stuck Injector Removal & Carbon Cleaning SOP | FuelPartsDB

Comprehensive workshop SOP for stuck diesel injector removal, pneumatic vibro-puller extraction, carbon solvent softening, and seat reaming without damage.

Read Technical Protocol

ASSEMBLY & INSTALLATION PROTOCOL

Diesel Injector Torque Specs & TTY Angles Guide

Common rail diesel injector hold-down bolt torque specs, TTY angles & pipe unions. Covers Bosch, Detroit DD13, Cummins & VAG 2.0 TDI workshop data in Nm.

Read Technical Protocol