0445110092
BOSCH 0445110092 Common Rail Injector for Hyundai H-1 Starex & Kia Sorento 2.5 CRDi
33800-4A000, 338004A000, 33800-4A000Y, 338004A000YF00VC01033DLLA156P11141600 barProduct Overview
The Bosch 0445110092 is a high-precision CRI2-16 solenoid common rail diesel fuel injector engineered for Hyundai H-1, H200, Starex, Libero, and Porter II commercial vehicles, as well as Kia Sorento I and Bongo III platforms powered by the 2.5L 16-valve turbocharged intercooled D4CB diesel engine (92 to 107 kW / 125 to 145 hp). Operating at peak rail pressures up to 1600 bar, this electro-hydraulic injector incorporates control valve F00VC01033, hole-type nozzle 0433171719 (stamped DLLA156P1114), magnet assembly F00VC30058, and seal ring kit F00VC99002. It complies with Euro 3 and Euro 4 light commercial vehicle emission standards and is fully interchangeable with Hyundai/Kia OE part numbers 33800-4A000, 338004A000, 33800-4A000Y, and 338004A000Y, Bosch factory remanufactured code 0986435154, and sister production units 0445110091, 0445110279, and 0445110306.
Vehicle & Engine Fitment
| Vehicle | Engine | Years |
|---|---|---|
| Hyundai H-1 / H200 2.5 CRDi MPV / Van | Hyundai / Kia D4CB 2.5 CRDi (2497 cc) | 2003-2006 |
| Hyundai Starex / Libero 2.5 CRDi Minibus / Van | Hyundai / Kia D4CB 2.5 CRDi (2497 cc) | 2002-2006 |
| Hyundai Porter II 2.5 CRDi Light Truck | Hyundai / Kia D4CB 2.5 CRDi (2497 cc) | 2004-2012 |
| Kia Sorento I 2.5 CRDi 4WD SUV | Hyundai / Kia D4CB 2.5 CRDi (2497 cc) | 2002-2009 |
| Kia Bongo III 2.5 CRDi Commercial Truck | Hyundai / Kia D4CB 2.5 CRDi (2497 cc) | 2004-2012 |
Technical Specifications
| Specification | Value |
|---|---|
| SKU | 0445110092 |
| Manufacturer | BOSCH |
| System Type | Common Rail Injector (CRI2-16 Solenoid) |
| Nozzle CodeCore Spec | 🔗 Shared Nozzle (2 assemblies):0445110091 |
| Control ValveCore Spec | |
| Magnet Assembly | F00VC30058 |
| Seal Ring Kit | F00VC99002 |
| Peak Pressure | 1600 bar |
| Emission Standard | Euro 3 / Euro 4 |
| Hold-Down Clamp Torque | 28-32 N·m📐 Torque & Angle Wizard → |
| High-Pressure Line Torque | 25-28 N·m (counter-held) |
| IMA Coding Required | No (Self-adapting via Bosch EDC15C7 / EDC16 ECU) |
| Solenoid Resistance | 0.25 - 0.45 Ohm at 20°C |
| 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
- Disconnect the vehicle battery and thoroughly clean the cylinder head area around the injector ports before removing old components.
- Extract the injector and use a dedicated seat cleaning brush and vacuum to remove all carbon crust down to bare aluminum.
- Inspect the new 0445110092 injector and fit a genuine new copper sealing washer onto the nozzle tip; apply high-temperature ceramic grease strictly to the injector shank (never on the nozzle tip).
- Lower the injector into the cylinder head bore and position the hold-down clamp squarely over the mounting shoulder.
- Install the clamp bolt and torque to 28-32 N·m to achieve uniform washer compression.
- Thread the high-pressure fuel pipe union by hand, then counter-hold the inlet fitting with an open-end wrench while torquing the union nut to 25-28 N·m.
- Connect the electrical harness plug (check resistance is 0.25-0.45 Ohm), reinstall the fuel leak-off line with new clips, prime the low-pressure fuel circuit, and inspect for leaks during initial warm-up.
- Never reuse old injector copper washers on D4CB engines; compressed washers lose elasticity, resulting in combustion gas blowby and tar-like carbon fouling.
- Always counter-hold the injector inlet hexagon when tightening high-pressure flare nuts to avoid twisting the injector body and binding internal control valve F00VC01033.
- If removing stubborn carbon-locked injectors, use a slide hammer adapter threaded onto the top body; never pry against the rocker cover or cylinder head rim.
Frequently Asked Questions
What symptoms indicate a failing 0445110092 injector on a Hyundai Starex or Kia Sorento 2.5 CRDi?
Typical failure symptoms include extended cranking when warm due to high backleakage past control valve F00VC01033, heavy black smoke under acceleration from nozzle DLLA156P1114 orifice wear, rough idling, engine misfire under load, and diagnostic trouble code P0087 (fuel rail pressure too low).
Does the Bosch 0445110092 injector require IMA classification coding on Hyundai D4CB engines?
Early generation D4CB Euro 3 engines equipped with Bosch EDC15C7 or early EDC16 engine control units do not require IMA coding. The ECU automatically compensates for minor cylinder variations through closed-loop idle speed and crankshaft acceleration adaptation.
Are Bosch 0445110092 and 0445110091 completely interchangeable?
Yes. Bosch 0445110091 and 0445110092 are direct sister part numbers manufactured for the Hyundai/Kia 2.5 CRDi D4CB engine platform. Both share identical hydraulic calibration, nozzle DLLA156P1114, valve F00VC01033, and OE cross-reference 33800-4A000.
What is the correct tightening torque for the injector clamp bolt on a Kia Sorento D4CB?
The M8 injector hold-down clamp bolt should be tightened to 28-32 N·m. Ensure the bolt threads and cylinder head hole are clean and free of oil to prevent hydraulic lock or thread stripping.
What bench test return leakage indicates a worn 0445110092 injector?
On an authorized common rail test bench at 1600 bar peak pressure, dynamic return leakage should not exceed 45 ml/min under full-load delivery and 25-30 ml/min at idle. Excessive backleakage indicates internal seat erosion on control valve F00VC01033.
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.