FuelPartsDB · WORKSHOP TECHNICAL SERVICE

DOC REF: SOP-CR-INJ-01

WORKSHOP INSTALLATION JOB SHEET & SOP

BOSCH 04451202890445120289 Bosch Perkins 1104D Injector: 2645A749 Data · Euro 3

Technician / Installer:

Date / Odometer:

Vehicle Reg / VIN:

Quality Sign-off:

CRITICAL INSTALLATION SPECIFICATIONS & TORQUES

Torques (Hold-down):26 N·m

Torques (Tightening):26 N·m

Copper washer:Renew the sealing washer on every installation. 1.50 mm standard; step up to 1.70 mm after light seat reaming, 2.00 mm after heavy seat refinishing.

IMA / ECU coding:Not required for this assembly

MANDATORY INSTALLATION CHECKLIST

[ ]Bore cleaned to bare metal using nylon/brass reaming brush & vacuumed (zero debris / no steel wire)
[ ]New copper sealing washer fitted with correct thickness (do not reuse old washer)
[ ]High-temperature ceramic paste applied to injector body shaft (never coat the nozzle tip)
[ ]Hold-down clamp bolt tightened in stage torque/angle sequence as specified
[ ]Fuel rail high-pressure line union torqued without tension or cross-threading
[ ]IMA / QR calibration code entered into diagnostic tool (Lexia/KTS/VCDS) for cylinder balancing
[ ]Low-pressure air bleed performed, engine idling leak-off test verified leak-free

BOSCH

0445120289

View Specs

SolenoidBosch Common Rail (CRIN2-16 solenoid, 0445120 series)Euro 3

0445120289 Bosch Perkins 1104D Injector: 2645A749 Data

Reference data for Bosch 0445120289 common rail injector · OEM 2645A749, 2645A737, 2645A745, 2645A746, 320-0670, 10R-7670 · Application Caterpillar C4.4 / C6.4 / C6.6 ACERT & Perkins 1104D / 1106D

Engine Platform:Caterpillar C4.4 / C6.4 / C6.6 ACERT & Perkins 1104D / 1106D →

OE REFERENCE2645A749, 2645A737, 2645A745, 2645A746, 320-0670, 10R-7670

CONTROL VALVEF00RJ02266

NOZZLEDLLA153P1721

RAIL PRESSURE1600 bar

EMISSIONTier 3 / Stage IIIA

WARRANTY12 Months

Compatible Injectors

OEM Ref

OE Nozzle

Vehicle & Engine Fitment

Vehicle	Engine	Years
Perkins 1104D-E44T / 1104D-E44TA Generator & Industrial	Caterpillar C4.4 / C6.4 / C6.6 ACERT & Perkins 1104D / 1106D	2008-2020
Caterpillar 416E / 420E / 428E Backhoe Loader & C4.4	Caterpillar C4.4 / C6.4 / C6.6 ACERT & Perkins 1104D / 1106D	2008-2020

Technical Specifications

Specification	Value
Injector Model	0445120289 (0986435555)
Perkins OE Part Numbers	2645A749, 2645A737, 2645A745
Caterpillar OE Numbers	320-0670, 10R-7670, 10R7670
Engine Platform	Perkins 1104D / CAT C4.4 (4.4L 4-Cyl)
Maximum Rail PressureCore Spec
Nozzle Tip ModelCore Spec
Hydraulic Control ValveCore Spec	🔗 Shared Valve (2 assemblies):0445120126
Clamp Bolt Torque	26 N·m (19 lb·ft)
Connector Tube Nut Torque	50 N·m (37 lb·ft)
Leak-Off Banjo Bolt Torque	15 N·m (11 lb·ft)
Combustion Copper Washer	1.5 mm (ID 7.7 mm / OD 15.0 mm)
ECU Calibration Type	Class Matched Fuel Quantity

Diagnostic Trouble Codes & Fault Protocols

Common diagnostic trouble codes (DTCs) triggered when this common rail injector experiences wear, circuit faults, or calibration drift:

P0087Critical

Fuel Rail / System Pressure Too Low

Excessive internal backleak from worn control valve seats drops common rail pressure below target under engine load.

P0087 Guide →🧪 Backleak Calculator

P0201 - P0208High

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.

P0201 Circuit Guide →

P0300 / P0301+High

Cylinder Misfire & Balancing Deviation

Carbon-clogged nozzle spray holes or missing IMA calibration causes uneven cylinder contribution. Recode ECM and verify washer seating.

P0300 Misfire Protocol →💻 IMA Coding Tool 📐 Washer Thickness

P0088High

Fuel Rail / System Pressure Too High

Spill line backpressure or stuck metering valve prevents rail depressurization, creating overpressure risks under load.

P0088 Guide →📊 Rail Pressure Converter

Browse all 61 Diesel Diagnostic Trouble Codes in our Workshop Hub ->

WORKSHOP PROTOCOLS

Technical Diagnostic & Service Protocols

Authoritative field procedures, diagnostic testing thresholds, and service SOPs for this assembly.

Workshop Diagnostic Protocol

Common Rail Injector Back-Leak Testing Guide

Common rail injector backleak test protocol. Graduated cylinder setup, warm idle & cranking limits in mL/min, control valve wear & P0087 diagnosis.

Read Technical Protocol

ECU Calibration Protocol

Bosch IMA Injector Coding & Location Guide

Bosch common rail injector IMA coding guide. Locate laser-etched 6-9 digit codes on body, ECU OBD2 adaptation steps & test bench calibration facts.

Read Technical Protocol

COMMON RAIL DIESEL WORKSHOP SOP

Stuck Injector Removal & Carbon Cleaning SOP | FuelPartsDB

Comprehensive workshop SOP for stuck diesel injector removal, pneumatic vibro-puller extraction, carbon solvent softening, and seat reaming without damage.

Read Technical Protocol

ASSEMBLY & INSTALLATION PROTOCOL

Diesel Injector Torque Specs & TTY Angles Guide

Common rail diesel injector hold-down bolt torque specs, TTY angles & pipe unions. Covers Bosch, Detroit DD13, Cummins & VAG 2.0 TDI workshop data in Nm.

Read Technical Protocol