0445120238
BOSCH 0445120238 Common Rail Injector for Dodge Ram 2500 / 3500 5.9 Cummins ISB
5263316, 3916991, 4940051, 3968158, 5254688, 5135790AB, 5135790AC, 5135790AD, 5135790AE, 5135790AF, R4429991, R5135790AB, R5135790AC, R5135790AD, R5135790AE, R5135790AFF00RJ02130DSLA124P55001600 barProduct Overview
The Bosch 0445120238 is a heavy-duty CRIN series solenoid-actuated common rail fuel injector engineered for commercial and light-heavy duty diesel engines operating under ETC and ETH engine designations. Designed to sustain peak dynamic system pressures of 1600 bar, this unit utilizes magnet assembly F00RJ02697 and control valve F00RJ02130 to achieve micro-second multi-pulse fuel metering across pilot, main, and post-injection events. Precision fuel atomization is delivered through nozzle 0433175516, ensuring optimal combustion efficiency and strict compliance with Euro 3, Euro 4, and Tier 3 emission standards.
Always cross-verify the engine build plate and existing OE part numbers (such as 5263316, 3916991, or 5135790AF) prior to installation on ETC and ETH engines. Following mechanical replacement of injector 0445120238, programming the injector quantity adjustment (IMA) / trim calibration codes into the ECU via a diagnostic scan tool is mandatory to restore balanced cylinder fuel delivery.
Vehicle & Engine Fitment
| Vehicle | Engine | Years |
|---|---|---|
| Dodge Ram 2500 5.9 ISB Pickup | Cummins ISBe / ISB / QSB 3.9L & 5.9L (Iveco NEF Tector) | 2002-2009 |
| Dodge Ram 3500 5.9 ISB Pickup / 4x4 | Cummins ISBe / ISB / QSB 3.9L & 5.9L (Iveco NEF Tector) | 2002-2009 |
| Cummins B5.9 ISB industrial / marine | Cummins ISBe / ISB / QSB 3.9L & 5.9L (Iveco NEF Tector) | 2002-2009 |
Technical Specifications
| Specification | Value |
|---|---|
| SKU | 0445120238 |
| Brand | BOSCH |
| Product Type | Complete Solenoid Common Rail Injector Assembly |
| Control ValveCore Spec | |
| Nozzle CodeCore Spec | |
| Engine Family | Cummins B-Series 5.9 ISB (ETC / ETH) |
| Operating PressureCore Spec | |
| Emission Standard | Euro 3 / Euro 4 / Tier 3 |
| Magnet Assembly | F00RJ02697 |
| Seal Ring Kit | F00RJ02176 |
Installation Tips
- Strictly enforce the two-wrench counter-hold procedure when tightening the high-pressure fuel connection: secure the injector inlet fitting with an open-end counter-hold wrench (typically 19 mm or 22 mm) while torquing the high-pressure fuel line union nut to 28-34 N·m, and torque the hold-down clamp bolt to 40-45 N·m to prevent torsional shear damage to the internal valve spindle of control valve F00RJ02130.
- Thoroughly decarbonize and clean the cylinder head injector bore and seating surface down to bare metal using a dedicated seat cutter and bore brush; install a new copper combustion washer from seal ring kit F00RJ02176 and apply a thin film of non-metallic, high-temperature ceramic anti-seize paste strictly to the injector body shaft (never on nozzle 0433175516) to prevent galvanic or carbon seizing in aluminum cylinder heads.
- Before cranking the engine, manually prime and bleed the low-pressure fuel supply circuit to purge trapped air that could cause dry-running cavitation inside control valve F00RJ02130, and register the new IMA / flow trim calibration data into the ECU using an OEM-level diagnostic tool.
Frequently Asked Questions
What is the OE cross-reference for this injector?
Bosch common rail injector 0445120238 cross-references directly to original equipment part numbers 5263316, 3916991, 4940051, 3968158, 5254688, 5135790AB, 5135790AC, 5135790AD, 5135790AE, 5135790AF, R4429991, R5135790AB, R5135790AC, R5135790AD, R5135790AE, and R5135790AF for ETC and ETH engine applications.
What control valve / actuator is used?
This CRIN series injector utilizes hydraulic control valve F00RJ02130 paired with high-speed electromagnetic magnet assembly F00RJ02697 and precision multi-hole nozzle 0433175516, sealed externally using components from seal ring kit F00RJ02176.
Does this injector require ECU IMA coding?
Yes. Even when manufacturing tolerances are tightly controlled, microscopic flow variations across control valve F00RJ02130 and nozzle 0433175516 require ECU adaptation. Entering the injector quantity adjustment (IMA) or calibration trim parameters via a diagnostic scan tool ensures accurate pilot and main injection pulse widths, preventing rough idle, combustion knock, and cylinder balancing fault codes.
What are the common failure symptoms and associated DTC codes?
Primary failure modes include erosion of the sealing seat in control valve F00RJ02130, coking or needle sticking in nozzle 0433175516, and electrical breakdown in magnet assembly F00RJ02697. Symptoms include extended cranking times, loss of rail pressure under load, white or black exhaust smoke, and fuel dilution of engine oil. Common Diagnostic Trouble Codes (DTCs) include P0087 (fuel rail pressure too low caused by excessive control valve seat wear and high return back-leakage), P0201-P0204 (injector actuator circuit open or short), and cylinder contribution/balancing codes P1011/P1012.
What are the proper installation torque specifications?
During installation of Bosch 0445120238, tighten the injector hold-down clamp bolt to an exact torque of 40-45 N·m to ensure uniform compression of the copper combustion seal without distorting the lower injector housing. Tighten the high-pressure fuel line union nut to 28-34 N·m while utilizing a secondary wrench to counter-hold the inlet fitting.
How do you perform a dynamic back-leakage flow bench test?
Mount injector 0445120238 on a calibrated common rail test bench capable of generating 1600 bar operating pressure. Measure dynamic return flow across multiple load points: acceptable idle back-leakage must remain <= 35 ml/min, and full-load return leak-off must not exceed <= 50 ml/min. Return flow exceeding 50 ml/min at 1600 bar indicates severe hydraulic seat erosion inside control valve F00RJ02130.
What is the acceptable solenoid coil electrical resistance?
Using a calibrated low-ohm digital multimeter at an ambient temperature of 20° Celsius, measure across the terminal pins of magnet assembly F00RJ02697. The acceptable solenoid coil resistance specification is 0.25-0.50 ohms, with complete electrical isolation (> 10 megohms) between the coil terminals and the metallic injector body.
Why is the two-wrench installation procedure strictly mandatory?
Applying 28-34 N·m of torque to the high-pressure fuel line union nut without supporting the injector inlet port transfers rotational torque directly into the injector body. This twisting force distorts the internal alignment of magnet assembly F00RJ02697 and causes micro-binding or shear damage to the precision-lapped valve spindle inside control valve F00RJ02130, resulting in immediate injector sticking or catastrophic return leak-off.
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.
Technical Diagnostic & Service Protocols
Authoritative field procedures, diagnostic testing thresholds, and service SOPs for this assembly.