0445120227
BOSCH 0445120227 Common Rail Injector for Weichai WP10 / WP12, Shacman & Foton Auman
612600080977, 612600080618, DZ91189360055F00RJ01692DLLA151P21821600 barProduct Overview
The Bosch 0445120227 is a heavy-duty CRIN2-16 common rail diesel fuel injector engineered for high-output commercial haulers powered by Weichai Power WP10 (9.7L) and WP12 (11.6L) turbodiesel platforms. Operating across Shacman Delong F2000/F3000/M3000, Foton Auman GTL/ETX, and Sinotruk Howo heavy tractor units, this unit functions at injection pressures up to 1600 bar. The hydraulic circuit incorporates control valve assembly F00RJ01692, hole-type nozzle 0433172182 (stamped DLLA151P2182), and magnet assembly F00RJ02697 to satisfy Euro 3 and Euro 4 heavy commercial emission standards. Common failure symptoms include excessive dynamic backleakage into the return fuel rail, prolonged hot-cranking, unburned black exhaust smoke under full acceleration, and loss of hauling power under heavy grade ascents.
CRITICAL FEED TUBE SEQUENCE: Never tighten the hold-down clamp before seating the high-pressure connector tube. Pre-torque the connector tube nut to 15 N·m first to align the spherical sealing interface with the injector inlet port, torque the hold-down clamp bolt to 24 N·m, and finally torque the connector tube to 50-55 N·m to prevent internal high-pressure leakage into the cylinder head and DTC P0087.
Vehicle & Engine Fitment
| Vehicle | Engine | Years |
|---|---|---|
| Shacman Delong F2000 / F3000 / M3000 Heavy Truck | Weichai WP10 / WP12 (9.7L & 11.6L Heavy Commercial) | 2008-2018 |
| Foton Auman ETX / GTL Heavy Duty Truck | Weichai WP10 / WP12 (9.7L & 11.6L Heavy Commercial) | 2009-2019 |
| Sinotruk Howo / Steyr King Commercial Truck | Weichai WP10 / WP12 (9.7L & 11.6L Heavy Commercial) | 2008-2017 |
| Beiben V3 / 2638 Heavy Haul Tractor | Weichai WP10 / WP12 (9.7L & 11.6L Heavy Commercial) | 2008-2018 |
Technical Specifications
| Specification | Value |
|---|---|
| Fuel System | Bosch Common Rail (CRIN2-16) |
| Peak Pressure | 1600 bar |
| Control ValveCore Spec | |
| Nozzle CodeCore Spec | 🔗 Shared Nozzle (2 assemblies):0445120228 |
| Nozzle Part NumberCore Spec | 🔗 Shared Nozzle (2 assemblies):0445120228 |
| Magnet Assembly | F00RJ02697 |
| Seal Ring Kit | F00RJ02176 |
| Connector Tube Pre-Torque | 15 N·m |
| Hold-down Clamp Torque | 24 N·m📐 Torque & Angle Wizard → |
| Connector Tube Final Torque | 50-55 N·m |
| High Pressure Line Torque | 30-35 N·m |
| Coding Standard | Bosch IMA (6/7-Character Alphanumeric) |
| 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 seat brush; blow out all carbon deposits and confirm zero debris remains.
- Fit a genuine new copper sealing washer of correct thickness (standard 1.5mm) onto the nozzle tip, and install a brand-new viton O-ring onto the injector body lubricated with clean engine oil.
- Lower the 0445120227 injector assembly straight into the bore, aligning the side fuel inlet port toward the cylinder head connector tube port, and snug the hold-down clamp bolt finger-tight (approx 3-5 N·m).
- Insert a new or meticulously inspected high-pressure connector tube (feed tube) through the cylinder head, 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 torque of 24 N·m to securely seat the copper washer against the cylinder head seat.
- Finalize torque on the high-pressure connector tube retaining nut to 50-55 N·m to establish a high-pressure metal-to-metal spherical seal.
- Connect the high-pressure fuel rail line using the 2-wrench counter-hold method, torque the line nut to 30-35 N·m, plug in the electrical solenoid harness, and programme the unique IMA calibration code into the ECM via diagnostic tool.
- High-Pressure Feed Tube Alignment Risk: Tightening the hold-down clamp bolt to 24 N·m before installing 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 -> 24 N·m -> 50-55 N·m torque progression.
- Inspect Feed Tube Sealing Tip: Whenever replacing injector 0445120227, examine 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 0445120227 injector on Weichai WP10 engines?
Common failure indicators include hard starting or extended cranking when warm due to excessive dynamic backleakage past control valve F00RJ01692, dense black exhaust smoke under acceleration caused by worn nozzle DLLA151P2182 orifices, engine knocking under load, and diagnostic trouble code P0087 (Fuel Rail Pressure Too Low).
Is ECU coding required after installing injector 0445120227?
Yes. The 0445120227 injector features an individually calibrated alphanumeric IMA code laser-etched onto the electrical connector head. This code must be written to the engine ECM (Weichai WISE, Bosch ESI, or universal commercial truck scanner) to enable individual cylinder fuel volume and timing corrections.
What are the common OE cross-reference numbers for 0445120227?
Primary OE part numbers include Weichai 612600080977, 612600080618, and Shacman DZ91189360055. The direct Bosch production counterpart is 0445120228.
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 F00RJ01692, causing rail pressure drop and hot-restart refusal.
What is the correct coil resistance for solenoid testing?
Using a calibrated digital multimeter at 20°C ambient temperature, measurement across the two solenoid pins must indicate 0.25 to 0.50 Ohms. Resistance below 0.20 Ohms indicates shorted internal windings, while resistance above 0.60 Ohms indicates degraded terminal bonding, either of which triggers 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.