0445110091
BOSCH 0445110091 for D4CB H-1/Starex - OEM 338004A000
33800-4A000, 33800-4A100, 33800-4A150, 33800-4A160, 33800-4A170, 3380004A000, 3380004A000YF00VC01033DLLA156P11141600 bar peak rail pressureProduct Overview
The BOSCH 0445110091 is a complete CRIN2 solenoid-type common rail injector assembly for Hyundai D4CB 2.5L CRDi engines. The F00VC01033 valve set meters fuel via a solenoid-actuated pilot valve, supporting up to 1600 bar peak rail pressure with stable multi-pulse injection sequencing. Shares the F00VC01033 valve group with sister SKUs 0445110092, 0445110185, 0445110186, 0445110279 - each carries a unique IMA calibration code and is NOT interchangeable without ECU re-flash. Fits Hyundai H-1 / Starex / Porter (2001-2011) and Kia Sorento (2002-2009) with D4CB engine family.
Always verify the OE number (338004A000) and engine build plate (D4CB) before ordering. IMA calibration code MUST match - sister SKUs with same F00VC01033 valve are NOT interchangeable.
Technical Specifications
| Specification | Value |
|---|---|
| SKU | 0445110091 |
| Brand | BOSCH |
| Type | Complete Injector Assembly (CRI2 solenoid) |
| OE Number | 33800-4A000 |
| Nozzle CodeCore Spec | 🔗 Shared Nozzle (2 assemblies):0445110092 |
| Nozzle Part NumberCore Spec | 🔗 Shared Nozzle (2 assemblies):0445110092 |
| Control ValveCore Spec | |
| Injection System | Bosch Common Rail (CRI2 solenoid, 0445110 series) |
| Operating PressureCore Spec | |
| Solenoid Resistance | 0.4-0.8 Ohm (low-impedance, peak-and-hold drive) |
| Net Weight | 600 g |
| Warranty | 12 months |
| Emission Standard | Euro 4 |
| Engine Family | D4CB (Hyundai A-series 2.5L CRDi) |
| Displacement | 2.5L (2497 cc, 91x96 mm bore/stroke) |
| Cylinders | 4 |
| Sister SKUs (same F00VC01033, NOT interchangeable) | 0445110092, 0445110185, 0445110186, 0445110279, 0445110730 |
| Magnet Assembly | F00VC30058 |
| Seal Ring Kit | F00VC99002 |
Installation Tips
- Disconnect battery negative terminal and depressurise fuel system (remove pump fuse, crank 3 times without starting) before any work on the D4CB fuel system.
- Remove HP fuel lines using 14 mm flare-nut wrenches; label each line for correct cylinder re-installation position.
- Clean the injector bore with bore brush; replace all copper sealing washers and O-rings - NEVER reuse old seals on the D4CB.
- Torque the injector clamp bolts to 28-33 N·m (OEM workshop manual spec: 28.4-33.4 N·m; stage 1: 15 N·m, final: 28-33 N·m using new bolt 33816-4A001). High-pressure line nuts: 25-28 N·m.
- Reconnect electrical connectors securely (D4CB uses 2-pin weatherpack connector; ensure correct polarity).
- Prime fuel system: key ON for 5 seconds, OFF for 10 seconds, repeat 3 times before cranking.
- After installation, clear fault codes P0201-P0204 and run a balance-rate test using GDS Mobile or a compatible scanner.
Frequently Asked Questions
How do I verify BOSCH 0445110091 is the correct replacement for my D4CB engine?
Check the OE number stamped on the solenoid body - it should read 338004A000 or match 0445110091. The D4CB engine build plate (on the timing cover or valve cover) confirms your engine family. The IMA calibration code is unique to each variant - sister SKUs 0445110092/0445110185/0445110186/0445110279 share the same F00VC01033 valve but are NOT interchangeable without ECU re-flash.
What is the control valve for 0445110091 and what SKUs share it?
The control valve is F00VC01033. This valve is shared by sister SKUs 0445110092, 0445110185, 0445110186, and 0445110279. All use the same solenoid assembly but carry different IMA calibration codes - they are grouped by valve type, not interchangeable.
Why is my 0445110091 not interchangeable with sister SKUs?
Despite sharing the F00VC01033 valve, each variant carries a unique IMA (Injection Quantity Adjustment) calibration code programmed into the ECU. Installing the wrong variant triggers fault codes P0201-P0204 and causes over-fueling (black smoke) or hard starting. Always verify the full OE number and IMA code match your application.
What are the common failure symptoms for 0445110091 on D4CB engines?
Typical failures: (1) P0201-P0204 injector circuit faults - often caused by failed solenoid coil or wiring harness chafing against the cylinder head; (2) white/black exhaust smoke from nozzle coking due to poor fuel quality; (3) hard cold start below 5°C from control valve wear reducing pilot injection; (4) fuel dilution in engine oil from cracked injector body. Common on D4CB at 150,000-200,000 km.
How do I test the 0445110091 solenoid with a multimeter?
Disconnect the electrical connector. Set multimeter to 200 Ohm range. Measure across the two solenoid terminals. D4CB specification: 0.4-0.8 Ohm (low-impedance, peak-and-hold). If reading is open circuit (>10 MOhm) or short circuit (<0.1 Ohm), replace the complete injector. Test cold (engine off 30+ minutes) for accurate results. Also check the harness connector for corrosion - D4CB injectors are prone to water ingress at the connector.
What fuel pressure does the D4CB CRDi system require?
The D4CB rail pressure spec is 1600 bar peak under full load. Low-pressure feed circuit requires 4-6 bar. If rail pressure drops below 1400 bar under load, suspect a worn F00VC01033 control valve or a failing high-pressure pump. Diagnose with GDS Mobile or Bosch KTS - do not replace injectors until HP pump output is verified.
Do I need to code the ECU after installing 0445110091?
Yes - the D4CB requires IMA (Injection Metering Adjustment) coding after any injector replacement. Use Hyundai GDS Mobile, Kia Global Diagnostic System, or a Bosch KTS with D4CB software. The coding process matches the new injector's IMA code to its cylinder position and learns the balance rate. Without coding, the engine runs in limp mode (reduced power, fault codes active).
What is the warranty on 0445110091?
12 months from invoice date. Covers manufacturing defects, solenoid coil failure, and valve seat wear. Does NOT cover damage from contaminated fuel, incorrect installation, water damage at the connector, or use beyond the D4CB rail pressure specification. Keep the Bosch installation diagnostic report and invoice for any warranty claim.
Is 0445110091 compatible with Euro 5 D4CB engines?
0445110091 is rated for Euro 4 D4CB applications (2001-2011). For Euro 5 D4CB engines (2012+), Hyundai/Kia used an updated injector variant with a different IMA calibration. Confirm your emission standard from the vehicle's build plate or registration documents before ordering - installing a Euro 4 injector in a Euro 5 D4CB will cause emissions compliance failures and fault codes.
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.