0445120393
BOSCH 0445120393 Common Rail Injector for FAW Jiefang J5 J6 & FAWDE CA6DL 8.6L
1112010-630, 1112010630, 1112010-630-0000, 11120106300000, 0986AD1014F00RJ01657DLLA150P16221600 barProduct Overview
The Bosch 0445120393 is a commercial heavy-duty CRIN2-16 common rail diesel fuel injector engineered for FAW Jiefang J5P, J6, J6L, and J6P commercial transport vehicles powered by FAWDE Xichai Aowei CA6DL (7.7L and 8.6L) turbodiesel engines. Serving as the official updated production replacement for early injector 0445120078, this unit operates at peak rail injection pressures up to 1600 bar. The precision hydraulic circuit integrates control valve assembly F00RJ01657 and hole-type nozzle 0433171991 (laser-stamped DLLA150P1622), complemented by solenoid magnet assembly F00RJ02703. Typical field wear manifests as excessive dynamic backleakage into the fuel return line, extended hot cranking, hard starting under cold ambient conditions, black exhaust smoke under load, and rail pressure collapse fault P0087.
CRITICAL CONNECTOR TUBE TORQUE SEQUENCE & DISPLACEMENT SEPARATION: Never tighten the hold-down clamp bolt before seating and pre-torquing the high-pressure connector tube. Pre-torque the connector tube retaining nut to 15 N·m first to align the spherical nose with the injector fuel inlet, torque the hold-down clamp bolt to 24 N·m, and finally torque the connector tube retaining nut to 50-55 N·m. Crucial workshop note: Do not confuse this 8.6L CA6DL injector (0445120393 / 0445120078, nozzle DLLA150P1622) with the 11.1L CA6DM2 unit (0445120277 / 0445120397, nozzle DLLA151P2240). Cross-mixing alters fuel spray geometry and causes cylinder over-fueling.
Vehicle & Engine Fitment
| Vehicle | Engine | Years |
|---|---|---|
| FAW Jiefang J6 / J6P Heavy Duty Truck | FAWDE Aowei CA6DL1 / CA6DL2 / CA6DM2 (7.7L - 11.1L) | 2008-2022 |
| FAW Jiefang J5P / Aowei Heavy Truck | FAWDE Aowei CA6DL1 / CA6DL2 / CA6DM2 (7.7L - 11.1L) | 2006-2018 |
| FAW Jiefang J6L Heavy Commercial Cargo | FAWDE Aowei CA6DL1 / CA6DL2 / CA6DM2 (7.7L - 11.1L) | 2011-2021 |
Technical Specifications
| Specification | Value |
|---|---|
| Fuel System | Bosch Common Rail (CRIN2-16) |
| Peak Pressure | 1600 bar |
| Control ValveCore Spec | |
| Nozzle CodeCore Spec | |
| Nozzle Part NumberCore Spec | |
| Magnet Assembly | F00RJ02703 |
| 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 clean and ream the cylinder head injector well down to bare metal using a brass seat cleaning brush; blow out all carbon debris with compressed air and confirm zero contaminants remain on the seating shoulder.
- Fit a brand-new genuine copper sealing washer (standard thickness 1.5mm) onto the nozzle tip, and lubricate the viton O-ring on the injector body with clean diesel engine oil prior to installation.
- Lower the 0445120393 injector vertically into the cylinder head bore, aligning the side fuel inlet port squarely with the high-pressure connector tube bore, and install the hold-down clamp bolt finger-tight (approx 3-5 N·m).
- Insert the clean high-pressure connector tube (feed tube) through the cylinder head until the spherical nose engages the injector body inlet, and tighten the connector tube retaining nut to the initial alignment torque of 15 N·m.
- Tighten the injector hold-down clamp bolt to its final torque specification of 24 N·m, ensuring even clamp pressure and complete seating of the copper washer.
- Finalize torque on the high-pressure connector tube retaining nut to 50-55 N·m to establish a metal-to-metal spherical seal capable of withstanding 1600 bar operating pressure.
- Connect the high-pressure fuel rail line using the 2-wrench counter-hold technique, torque the union nut to 30-35 N·m, attach the electrical solenoid harness, and programme the laser-etched IMA calibration code into the vehicle ECM.
- Connector Tube Torquing Protocol: Never torque the hold-down clamp to 24 N·m before installing the high-pressure connector tube. Clamp loading tilts the injector micro-angularly, preventing the connector tube spherical nose from concentric engagement. This causes high-pressure fuel leakage into the engine oil and fault code P0087. Adhere strictly to the 15 N·m -> 24 N·m -> 50-55 N·m progression.
- Connector Tube Tip Inspection: Whenever replacing injector 0445120393, inspect the spherical sealing surface of the connector tube. Any pitting, scoring, or edge erosion requires immediate tube renewal; reusing a worn tube prevents high-pressure sealing regardless of torque applied.
- 2-Wrench Counter-Hold Mandate: When tightening the fuel line union nut to 30-35 N·m, always counter-hold the connector tube retaining nut with an open-ended wrench to prevent twisting or shearing the injector inlet body.
Frequently Asked Questions
What engine models use the Bosch 0445120393 injector?
The Bosch 0445120393 common rail injector is engineered for FAWDE Xichai Aowei CA6DL platforms (including CA6DL1 7.7L and CA6DL2 8.6L engines rated up to 258kW / 350 HP), powering FAW Jiefang J5P, J6, J6L, and J6P commercial heavy trucks.
Is Bosch 0445120393 interchangeable with 0445120078?
Yes. The 0445120393 is Bosch's official direct superseding replacement for the earlier 0445120078 injector on FAW CA6DL engines, sharing identical nozzle geometry (DLLA150P1622), control valve (F00RJ01657), and OE part numbers (1112010-630).
What is the difference between 0445120393 and 0445120277?
While both equip FAW Jiefang trucks, 0445120393 is designed for the 7.7L/8.6L CA6DL engine (nozzle DLLA150P1622, OE 1112010-630), whereas 0445120277 is designed for the larger 11.1L CA6DM2 engine (nozzle DLLA151P2240, OE 1112010-M10-0000). They must not be interchanged due to different combustion chamber flow rates.
What is the correct tightening torque sequence for 0445120393?
Pre-torque the high-pressure connector tube nut to 15 N·m to establish concentric alignment, torque the hold-down clamp bolt to 24 N·m, and finally torque the connector tube retaining nut to 50-55 N·m.
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.