0445120165
BOSCH 0445120165 Yuchai YC6J EU4 Injector
J0100-1112100-A38F00RJ02806DLLA150P21231600 bar peak rail pressureProduct Overview
The BOSCH 0445120165 is a complete injector assembly engineered for the Yuchai YC6J EU4 heavy-duty platform. The F00RJ02806 solenoid control valve meters fuel flow via current-driven pilot injection, supporting a 1600 bar peak rail pressure with stable multi-pulse combustion across main injections per cycle. The DLLA150P2123 nozzle (8 holes, 0.145mm hole diameter, 150° spray angle, Bosch P/N 0433172123) atomizes fuel into the 105x125 mm bore of the YC6J's 6.494L inline-6 cylinder block. Output range: 118-199 kW (160-270 HP), peak torque 950 N·m at 1200-1700 rpm. Common applications include 8.5-11m city buses (Yutong, Higer, Kinglong), 9-10m school buses, and 6-12 tonne medium-duty cargo trucks. The YC6J family has been in continuous production for over 20 years with a B10 service life of 700,000 km.
Verify the IMA calibration code on the solenoid body and the J0100-1112100-A38 OE stamp before installation. 0445120165 uses control valve F00RJ02806 (with F00RJ02703 solenoid magnet cap) and DLLA150P2123 nozzle (0433172123). It is NOT interchangeable with 0445120164 (YC6JA, 6.5L) - the IMA calibration differs.
Vehicle & Engine Fitment
| Vehicle | Engine | Years |
|---|---|---|
| Yutong ZK6932D / ZK6932HG | YC6J / YC6JA / YC4G | 2010-2015 |
| Higer KLQ6129 / KLQ6826 | YC6J / YC6JA / YC4G | 2011-2016 |
| King Long XMQ6900Y / XMQ6930Y | YC6J / YC6JA / YC4G | 2012-2017 |
| Dongfeng EQ5168 / EQ5250 | YC6J / YC6JA / YC4G | 2010-2016 |
| Foton BJ5163 / BJ5253 | YC6J / YC6JA / YC4G | 2011-2016 |
| Yutong ZK6119 school bus | YC6J / YC6JA / YC4G | 2010-2014 |
Technical Specifications
| Specification | Value |
|---|---|
| SKU | 0445120165 |
| Brand | BOSCH |
| Type | Complete Injector Assembly |
| OE Number | J0100-1112100-A38 |
| Aftermarket PN | A4600170312 |
| Nozzle CodeCore Spec | |
| Nozzle Part NumberCore Spec | |
| Nozzle SpecsCore Spec | |
| Control ValveCore Spec | |
| Magnet Assembly | F00RJ02703 |
| Overhaul Kit | F00RJ03496 |
| Injection System | Common Rail (BOSCH high-pressure) |
| Operating PressureCore Spec | |
| Solenoid Voltage | 12V DC |
| Solenoid Resistance | 0.5-2.0 ohm (cold) |
| Material | High-speed steel body, hardened nozzle |
| Net Weight | 600 g |
| Warranty | 12 months |
| Emission Standard | Euro 4 (also fits Euro 3 applications) |
| Engine Family | Yuchai YC6J |
| Engine Displacement | 6.494 L (105x125 mm bore/stroke) |
| Cylinders | 6 (inline) |
| Power Output | 118-199 kW (160-270 HP) |
| Peak Torque | 950 N·m at 1200-1700 rpm |
| Vehicle Application | 8.5-11m buses, 9-10m school buses, 6-12T medium trucks |
| Service Life B10 | 700,000 km |
Installation Tips
- Execute the mandatory two-wrench counter-hold method when securing high-pressure line fittings: hold the injector inlet connector steady using an open-ended counter-hold wrench while torquing the fuel rail delivery pipe nut to 45-55 N·m, preventing any rotational displacement of the injector or damage to internal seals.
- Thoroughly clean the cylinder head injector bore down to the base metal using a non-abrasive brass cleaning brush, discard the used copper washer, and fit a new seal from Seal Ring Kit F00RJ02176; apply a thin, uniform film of high-temperature ceramic anti-seize paste exclusively along the injector body shaft, ensuring no paste contacts the nozzle tip, nozzle cap nut, or copper seating surface.
- Torque the hold-down clamp bolt to 28-32 N·m (follow Yuchai workshop manual for YC6J engine). Write the individual multi-digit IMA trim code stamped on the solenoid body into the ECU using an authorized diagnostic scan tool, then manually prime and vent the low-pressure fuel circuit before cranking to avoid cavitation damage to Control Valve F00RJ02806 and Nozzle 0433172123.
Frequently Asked Questions
How do I verify BOSCH 0445120165 is the correct replacement for my Yuchai YC6J?
Check the OE stamp on the solenoid body matches J0100-1112100-A38 (the Yuchai OEM reference for YC6J EU4). The 10-digit SKU 0445120165 should match the build plate on the original injector. The IMA calibration code is unique - cross-reference via BOSCH ESI or your Yuchai dealer for the exact match. Do NOT substitute 0445120164 (which fits YC6JA, 6.5L) - different IMA code, will trigger P0201.
What is the control valve code for 0445120165?
F00RJ02806 is the primary hydraulic control valve assembly, paired with solenoid magnet cap F00RJ02703 and overhaul kit F00RJ03496. Same valve group as sister SKU 0445120164 but different IMA calibration per SKU - NOT interchangeable without ECU re-flash.
Why is my 0445120165 not interchangeable with 0445120164?
Despite both sharing the F00RJ02806 control valve family, 0445120165 (YC6J EU4, DLLA150P2123) and 0445120164 (YC6JA 6.5L, DLLA150P1827+) carry different nozzles and different IMA (Injection Quantity Adjustment) calibration codes. Installing 0445120164 in a YC6J application triggers P0201-P0206 fault codes and may cause over-fueling (black smoke) or hard starting. Always verify the OE number (J0100-1112100-A38 for 0445120165) and IMA code match your specific application.
What are the common failure modes for 0445120165 in YC6J city buses?
Typical failures include: (1) solenoid coil open-circuit (P0201 fault) after 100,000-150,000 km; (2) nozzle coking from poor fuel quality (P0300 random misfire, black smoke); (3) control valve F00RJ02806 wear causing over-fueling; (4) injector body crack from thermal cycling; (5) high-pressure line sealing washer failure. Bus applications with frequent idle-stop cycles are particularly susceptible. Recommend replacement at 200,000 km or first symptom.
How to test 0445120165 solenoid with multimeter?
Disconnect the electrical connector, set multimeter to ohms (200 ohm range), measure across the two solenoid terminals. Normal resistance: 0.5-2.0 ohm at room temperature (cold engine, off for 30 min). Open circuit (>10 M ohm) = replace injector. Short circuit (<0.1 ohm) = replace. Always test cold for accurate reading.
What fuel pressure does 0445120165 require in a YC6J application?
Peak rail pressure is 1600 bar in the YC6J EU4 common rail system. Low-pressure feed must be 4-6 bar. If the rail pressure drops below 1500 bar under load, suspect a worn F00RJ02806 control valve or clogged DLLA150P2123 nozzle - replace as a set.
Can I install 0445120165 myself?
Mechanical install is straightforward (15mm/17mm wrenches, 45-55 N·m torque), but ECU re-flash for the IMA calibration requires BOSCH diagnostic equipment (KTS 590 or ESI Tronic). Most workshops handle this in 2-3 hours total. Critical: use the 2-wrench procedure (15mm on solenoid, 17mm on high-pressure line) - never apply force directly to the solenoid body or you will damage the valve.
What is the warranty on 0445120165?
12 months from invoice date, covers manufacturing defects and solenoid failure. Warranty does not cover damage from contaminated fuel (especially water in fuel, common in city bus applications), incorrect installation (e.g. using force on solenoid without 2-wrench procedure), or operation beyond rated pressure. Keep installation record and BOSCH diagnostic log for any warranty claim.
Is 0445120165 compatible with Euro 3 emissions?
0445120165 is rated for Euro 4 (YC6J180-42 / 200-42 / 220-42 / 245-42). It can also be used in Euro 3 applications (YC6J180-30 / 200-30 / 220-30 / 245-30 / 270-30) because the F00RJ02806 control valve and DLLA150P2123 nozzle are shared across emission variants. For Euro 5 (YC6J180-52 / 200-52 / 220-52 / 245-52), the system adds SCR post-treatment but the injector itself is typically the same - confirm with your dealer for the exact SCR-equipped variant.
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.