0445120081
BOSCH 0445120081 Common Rail Injector for FAW Jiefang & King Long Bus Xichai CA4DF / CA6DF
1112010470, 1112010B470-0000F00RJ01692DLLA151P16561600 barProduct Overview
The Bosch 0445120081 common rail diesel injector is an authentic CRIN2 solenoid-actuated unit engineered for FAW Xichai (Wuxi Diesel) CA4DF and CA6DF commercial diesel engines, widely fitted in heavy-duty trucks and King Long buses. Operating at a peak injection pressure of 1600 bar, this Euro 3 and Euro 4 compliant injector utilizes the precision Bosch hole-type nozzle DLLA151P1656 (part number 0433172017) coupled with the durable F00RJ01692 control valve assembly. Built to withstand punishing duty cycles, the injector delivers multi-injection events for optimal combustion and low emissions. Common operational failure modes include internal control valve wear and nozzle carbon fouling, manifesting in excessive fuel return flow, hard starting under load, erratic idle, black exhaust smoke, and diagnostic rail pressure drop fault codes. Replacement mandates clean fuel circuit flushing and precise ECU IMA coding calibration.
Before installation, verify OEM casting reference 1112010470 and ensure individual injector IMA QR codes are programmed into the engine ECU to maintain balanced cylinder injection quantities.
Technical Specifications
| Specification | Value |
|---|---|
| SKU | 0445120081 |
| Brand | FAW / King Long / Dongfeng / BOSCH |
| Type | Complete Injector Assembly (Bosch Common Rail (CRIN2 solenoid)) |
| OE Number | 1112010470, 1112010B470-0000 |
| Control ValveCore Spec | |
| Nozzle CodeCore Spec | |
| Internal Nozzle P/NCore Spec | |
| Injection System | Bosch Common Rail (CRIN2 solenoid) |
| Operating PressureCore Spec | |
| Torque Spec | 30 N·m |
| Hold Down Torque | 35 N·m |
| Warranty | 12 Months |
| Emission Standard | Euro 3 / Euro 4 |
| Engine Family | FAW Xichai CA4DF / CA6DF (4.75L - 7.12L) |
| Coding Required | Yes (IMA Code) |
Installation Tips
Tools needed: 10mm & 11mm flare nut wrench (rail and injector inlet unions), Injector slide hammer / mechanical puller kit (if seized), Injector seat cleaning brass brush set & industrial vacuum, Seat reaming tool (if carbon erosion is present), Torque wrench (2 N·m - 40 N·m range), ECU diagnostic scan tool with IMA/QR coding capability, Digital micrometer / depth gauge for copper washer check
- Disconnect Battery & Relieve Rail Pressure: Isolate negative battery terminal and verify rail residual pressure drops below 10 bar via live diagnostics before cracking fuel fittings.
- Clean Engine Bay & Injector Recesses: Thoroughly blast away grit, oil slurry, and loose dirt around cylinder head injector wells using compressed air and degreasing solvent.
- Label Wiring Harness & Spill-Off Connectors: Tag each cylinder harness connector and gently disengage delicate plastic spill-off return rail clips.
- Remove High-Pressure Supply Lines: Back off high-pressure union nuts with a flare-nut wrench; IMMEDIATELY cap all open fuel rail orifices and injector inlets with clean blanking caps.
- Extract Hold-Down Clamp Fasteners: Back out hold-down clamp bolts. Note that torque-to-yield stretch bolts must always be discarded and never reused.
- Extract Injector Body: Withdraw injector vertically. If carbon-bonded or coked, attach an approved mechanical slide-hammer puller to the inlet adaptor without rotating the injector body.
- Inspect Injector Well & Bore: Ensure old copper seal washer has not remained fused at the base of the cylinder head seat; remove with a brass retrieval pick if stuck.
- Clean & Ream Injector Seat: Ream and burnish injector seating face using dedicated seat cutter brushes and industrial vacuum until seat is 100% bare, flat metal.
- Install New Copper Sealing Washer: Mount an OEM-specification copper washer of designated thickness (standard 1.5mm-2.0mm) using high-temp grease to hold in position.
- Fit Injector with Ceramic Anti-Seize: Lightly coat the injector body barrel with approved high-temperature ceramic grease; keep nozzle tip and copper washer strictly dry and clean.
- Torque Hold-Down Clamp to Spec: Secure hold-down clamp bolts and torque to factory specified stages (35 N·m) using a calibrated torque wrench.
- Refit High-Pressure Delivery Pipes: Thread union nuts by hand to avoid cross-threading, then tighten injector inlet and rail unions to 30 N·m evenly.
- Reconnect Return Leak-Off Line & Harness: Push on leak-off return clips until retaining collars click home; reattach electrical plug and lock harness tab firmly.
- ECU IMA / QR Code Calibration & Fuel Priming: Program the unique alphanumeric IMA/QR calibration code etched on the injector head into the corresponding ECU cylinder address; prime fuel system prior to initial cranking.
- CRITICAL IMA CALIBRATION: Never operate the engine without programming the new IMA/QR trim code into the ECU map — uncalibrated injectors cause combustion knocking, cylinder imbalance, and premature DPF clogging.
- CRITICAL COPPER WASHER REPLACEMENT: Always install brand new copper crush washers and torque-to-yield clamp bolts — reusing old seals leads to catastrophic combustion gas leakage ('black death' buildup).
- HOSPITAL-GRADE FUEL CLEANLINESS: A microscopic contamination particle as small as 5 microns can jam the internal F00RJ01692 valve or needle — ensure all fuel line plugs stay on until final connection.
- STRICT HOLD-DOWN TORQUE: Adhere strictly to the 35 N·m tightening sequence — overtightening distorts the injector body and binds the needle.
Frequently Asked Questions
Does Bosch injector 0445120081 require ECU coding (IMA / QR code)?
Yes, Bosch injector 0445120081 requires cylinder-specific IMA calibration code programming into the engine control unit (ECU). Each unit has a unique multi-character calibration code stamped on its electrical connector body or solenoid head that defines fuel delivery tolerances across multiple rail pressure points. Programming this code via a diagnostic scanner (Bosch KTS, VCDS, ODIS, INPA/ISTA, or Autel MaxiSys) is mandatory to ensure balanced cylinder idle, Euro 3 / Euro 4 emissions compliance, and smooth throttle response.
What are the most common symptoms of a failing 0445120081 injector on FAW / King Long / Dongfeng FAW Xichai CA4DF / CA6DF (4.75L - 7.12L)?
Common symptoms include prolonged cold-start cranking, rough or oscillating idle, black exhaust smoke under acceleration (nozzle needle wear/over-fueling), white smoke on startup (unburnt fuel spray), ticking/clattering under load, increased fuel consumption, cylinder misfire trouble codes (P0201-P0206 / P0300-P0306), and high fuel spill-off return rates causing low rail pressure fault codes under heavy acceleration.
Should I replace injectors individually or as a complete set?
While replacing a single failed injector is acceptable if fuel contamination is ruled out, industry best practice on engines with over 150,000 km is to replace or bench-test all injectors as a complete set. Wear across the high-pressure control valve (F00RJ01692) and nozzle (DLLA151P1656) occurs evenly across all cylinders; fitting one new unit alongside worn units often leads to noticeable idle vibration due to delivery quantity variance.
Why must the copper crush washer and hold-down bolt be replaced on every install?
The copper washer forms the critical gas-tight seal between the injector nozzle and the cylinder head combustion chamber. During combustion, temperatures exceed 1,500°C and pressures surpass 150 bar. A compressed washer work-hardens and will not re-seal properly. Furthermore, most hold-down clamp bolts are torque-to-yield (stretch) fasteners designed for single use; reusing them risks bolt snapping inside the cylinder head or loss of clamp tension.
What preventative maintenance is required after installing replacement 0445120081 injectors?
Always replace the diesel fuel filter with a high-efficiency OEM-spec filter (3 to 5 micron rating), inspect the fuel tank and fuel lines for metallic swarf from high-pressure pump wear, flush the common rail if debris is present, use high-quality EN590 diesel, and verify injector smooth running balance values with diagnostic software after 500 km of driving.
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.