0445120066
BOSCH 0445120066 Common Rail Injector for Volvo D7E EC240B EC290B & Renault DXi 7
20798114, 20430583, 20798683, 04289311, 04290986, 7420798114F00RJ01479DLLA144P15651600 barProduct Overview
The Bosch 0445120066 is an industrial heavy-duty common rail diesel injector built on the robust CRIN2-16 platform, specifically engineered for high-hour off-highway crawler excavators and commercial heavy machinery powered by Volvo D7E (7.2L 6-cylinder) and Deutz TCD 2013 L6 4V turbocharged diesel engines. Standard equipment across Volvo EC240B, EC240C, EC290B, EC290C hydraulic excavators, L110E / L120E wheel loaders, and Renault Premium DXi 7 commercial haulers, this solenoid injector delivers multiple precision fuel injections at system pressures up to 1600 bar. Internal hydraulics feature precision control valve set F00RJ01479, hole-type nozzle 0433171964 (stamped DLLA144P1565), and magnet assembly F00RJ02703. Primary equipment cross-references include Volvo OE 20798114, 20430583, 20798683, Deutz OE 04289311, 04290986, and Bosch factory remanufactured unit 0986435548.
HOLD-DOWN CLAMP TORQUE & NOZZLE SEAT PRECAUTION: When mounting injector 0445120066 on Volvo D7E and Deutz TCD 2013 engines, always replace the copper base washer with genuine Bosch F00RJ01453 (7.73 x 14.36 x 1.49 mm). Clean the cylinder head sleeve bore down to bare metal using a brass wire seat brush. Tighten the hold-down clamp bolt progressively to 28-32 N·m (or 15 N·m initial torque followed by a final tightening angle per engine manual). Reusing crushed copper washers leads to combustion gas blow-by, black death carbon buildup, and rapid control valve seat erosion resulting in hot no-start and DTC P0087.
Vehicle & Engine Fitment
| Vehicle | Engine | Years |
|---|---|---|
| Volvo EC240B / EC240C Excavator | Deutz TCD 2012 / 2013 & Volvo D6E / D7E (4.8L - 7.2L) | 2005-2016 |
| Volvo EC290B / EC290C Excavator | Deutz TCD 2012 / 2013 & Volvo D6E / D7E (4.8L - 7.2L) | 2005-2016 |
| Volvo L110E / L120E Wheel Loader | Deutz TCD 2012 / 2013 & Volvo D6E / D7E (4.8L - 7.2L) | 2006-2015 |
| Renault Midlum / Premium DXi 7 Truck | Deutz TCD 2012 / 2013 & Volvo D6E / D7E (4.8L - 7.2L) | 2006-2014 |
Technical Specifications
| Specification | Value |
|---|---|
| Fuel System | Bosch Common Rail (CRIN2-16) |
| Peak Pressure | 1600 bar |
| Control ValveCore Spec | 🔗 Shared Valve (2 assemblies):0445120067 |
| Nozzle CodeCore Spec | |
| Nozzle Part NumberCore Spec | |
| Magnet Assembly | F00RJ02703 |
| Seal Ring Kit | F00RJ02176 |
| Hold-down Clamp Torque | 28-32 N·m📐 Torque & Angle Wizard → |
| High Pressure Line Torque | 30-35 N·m |
| Coding Standard | Bosch IMA (6/7-Character Alphanumeric) |
| Operating PressureCore Spec |
Installation Tips
Tools needed: Calibrated precision torque wrench (10-60 N·m scale), Brass injector bore cleaning brush kit and industrial vacuum cleaner, Dedicated diagnostic scanner capable of writing Bosch IMA calibration codes
- Scrape and brush the copper washer seating area inside the cylinder head bore down to bare copper/aluminum using a brass rotary brush, vacuuming out all loose carbon debris.
- Fit a brand-new genuine copper combustion seal washer (Bosch F00RJ01453, 1.49 mm thickness) over the nozzle tip, and slide a new viton body O-ring into place lightly coated with clean engine oil.
- Lower the 0445120066 injector straight into the cylinder head sleeve bore, ensuring the electrical connector faces the wiring loom channel and the fuel inlet aligns with the rail pipe line.
- Position the hold-down clamp over the injector shoulder and thread the clamp bolt finger-tight, verifying the injector sits fully upright without cocking.
- Torque the hold-down clamp bolt progressively in two steps to the final manufacturer specification of 28-32 N·m to achieve uniform plastic crush of the copper gasket.
- Thread the high-pressure fuel supply pipe union nut by hand to prevent cross-threading, then torque to 30-35 N·m using a flare-nut crowfoot adapter while counter-holding the inlet fitting.
- Snap the 2-pin electrical wiring connector into the solenoid terminal until locked, and write the individual IMA calibration code into the Volvo / Deutz EMS via diagnostic software.
- Copper Washer Thickness Integrity: Never install two copper washers under the nozzle tip or reuse a flattened old gasket. Increasing washer thickness lifts the nozzle spray holes above the piston bowl rim, causing poor atomization, excessive exhaust smoke, and cylinder balance misfire.
- High-Pressure Fuel Flushing: Prior to connecting the high-pressure steel lines to new injectors, crank the starter for 5 seconds with lines cracked open into a catch container to expel line contaminants. Particles above 2 microns will ruin the micro-finished seat of valve F00RJ01479.
- IMA Coding Requirement: Injector 0445120066 features an individual alphanumeric IMA calibration code stamped onto the magnet head. Inputting this code into the engine control module calibrates pre-injection quantity and compensates for manufacturing tolerances across all operating speeds.
Frequently Asked Questions
What symptoms indicate a failing Bosch 0445120066 injector on Volvo EC240B / EC290B excavators?
Typical signs include hard starting or long cranking when warm due to excessive dynamic backleakage past control valve F00RJ01479, thick black smoke under hydraulic load from worn nozzle DLLA144P1565 orifices, engine hunting/rough idle, and fault code P0087 (Rail Pressure Too Low).
Is ECU IMA coding mandatory when replacing injector 0445120066?
Yes. The 0445120066 injector features a calibrated alphanumeric IMA code on the solenoid head. Registering this code into the engine ECM (Volvo Tech Tool or commercial diagnostic scanner) adjusts individual cylinder fuel delivery and timing maps.
What are the common OE cross-reference numbers for 0445120066?
Primary OEM part numbers include Volvo 20798114, VOE20798114, 20430583, 20798683, Deutz 04289311, 04290986, 04290987, and Renault Trucks 7420798114. Bosch exchange remanufactured unit is 0986435548.
What dynamic backleak rate is acceptable during bench testing?
At normal operating temperature under full load rail pressure (1600 bar), maximum permissible return leakage should not exceed 45 ml/min per injector. Dynamic backleak exceeding 50 ml/min confirms internal valve seat erosion in F00RJ01479, causing hot-restart failure.
What is the correct coil resistance for solenoid testing?
Using a calibrated digital multimeter at 20°C ambient temperature, measurement across the two solenoid terminals must read between 0.25 and 0.50 Ohms. Resistance below 0.20 Ohms indicates shorted internal coils, while resistance above 0.60 Ohms indicates degraded terminal bonding.
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.