0445120030
BOSCH 0445120030 Common Rail Injector for MAN TGA 18.310-41.430 D2066 10.5L
51101006032, 51101006035, 51101006048, 51101006125, 51101009125, 51.10100-6032, 51.10100-6125F00RJ01218DLLA146P13391600 barProduct Overview
The Bosch 0445120030 is a heavy-duty CRIN2-16 commercial vehicle common rail diesel fuel injector engineered for MAN TGA heavy trucks (models 18.310 through 41.430) powered by the 10.5L D2066 inline-six turbodiesel engine family (including D2066 LF01 to LF07 variants, rated from 228 kW / 310 HP to 316 kW / 430 HP). Operating at fuel rail pressures up to 1600 bar, this assembly utilizes control valve F00RJ01218, hole-type nozzle 0433171831 (stamped DLLA146P1339), and magnet assembly F00RJ02703 to deliver precise multi-injection timing satisfying Euro 3 commercial emission standards. High-hour workshop failure symptoms include excessive dynamic fuel backleakage into the return fuel rail, hard starting or extended hot cranking, dense black smoke under heavy grade pulling, and diagnostic fault code P0087 resulting in engine power derating.
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 fault code P0087.
Vehicle & Engine Fitment
| Vehicle | Engine | Years |
|---|---|---|
| MAN TGA 18.310 / 18.350 / 18.390 / 18.430 Commercial Tractor | MAN D2066 LF / LOH (10.5L Common Rail) | 2004-2010 |
| MAN TGA 26.310 / 26.350 / 26.390 / 26.430 Heavy Haul Truck | MAN D2066 LF / LOH (10.5L Common Rail) | 2004-2010 |
| MAN TGA 33.350 / 33.390 / 33.430 Heavy Construction Truck | MAN D2066 LF / LOH (10.5L Common Rail) | 2004-2010 |
| MAN TGA 41.350 / 41.390 / 41.430 8x4 Heavy Hauler | MAN D2066 LF / LOH (10.5L Common Rail) | 2004-2010 |
Technical Specifications
| Specification | Value |
|---|---|
| Fuel System | Bosch Common Rail (CRIN2-16) |
| Peak Pressure | 1600 bar |
| Control ValveCore Spec | 🔗 Shared Valve (2 assemblies):0445120061 |
| Nozzle CodeCore Spec | |
| Nozzle Part NumberCore Spec | |
| Magnet Assembly | F00RJ02703 |
| 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 (Early CRIN2 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 cleaning brush; blow out all carbon deposits and confirm 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 body O-ring with clean engine oil.
- Lower the 0445120030 injector assembly straight into the cylinder head bore, aligning the lateral high-pressure fuel inlet socket with the transverse cylinder head connector tube port.
- 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 specification 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 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 0445120030, 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 0445120030 injector on MAN D2066 engines?
Common failure indicators include extended cranking when warm due to excessive dynamic backleakage past control valve F00RJ01218, rough engine idle, dense black exhaust smoke under acceleration from nozzle DLLA146P1339 wear, and fault code P0087 (Rail Pressure Below Minimum).
Is ECU coding required after installing injector 0445120030?
No. The Bosch 0445120030 is an early production CRIN2 commercial injector that does not require IMA/IQA calibration code programming. The MAN EDC7 engine control unit automatically adjusts cylinder individual fuel delivery via closed-loop crankshaft speed monitoring.
What are the primary OE part numbers for 0445120030?
Primary MAN OEM references include 51101006032, 51101006035, 51101006048, 51101006125 (51.10100-6125), and 51101009125. Bosch remanufactured exchange number is 0986435517.
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 F00RJ01218, causing rail pressure drops and hot-restart refusal.
What is the correct coil resistance for solenoid testing?
Measured across the two solenoid pins at 20°C ambient temperature, coil resistance must indicate 0.25 to 0.50 Ohms. Resistance outside this range indicates shorted internal windings or degraded bonding, triggering 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.