0445110479
BOSCH 0445110479 Common Rail Injector for Opel Insignia / Astra J / Zafira C 2.0 CDTI A20DTH Euro 5
55566050, 0821035, 0821019, 0986435234 F00VC01359 DLLA152P2344 1800 bar Product Overview
The Bosch 0445110479 is a high-precision Euro 5 common rail solenoid injector designed for Opel / Vauxhall passenger and crossover models powered by the GM Family B 2.0 CDTI diesel engine family (A20DTH, A20DTJ, A20DTR). Engineered on Bosch CRI2-18 architecture, this injector operates at a peak common rail pressure of 1800 bar. It incorporates the advanced multi-hole DLLA152P2344 nozzle and F00VC01359 control valve assembly to achieve rapid needle response and ultra-fine fuel atomization required for Euro 5 DPF regeneration cycles. Direct replacement for GM/Opel OE numbers 55577668, 55566050, 0821035, and Bosch remanufactured part 0986435234. Full ECU IMA code calibration is strictly mandatory following installation.
Verify the GM OE number (55577668 / 55566050) on the injector head. Bosch 0445110479 operates at 1800 bar peak pressure. Cylinder-specific IMA trim coding and installation with new stretch bolts (25 N·m + 30°) are mandatory.
Compatible Injectors
Vehicle & Engine Fitment
| Vehicle | Engine | Years |
|---|---|---|
| Opel Insignia A (G09) 2.0 CDTI | A20DTH 160hp / 163hp | 2008-2017 |
| Opel Astra J (P10) 2.0 CDTI | A20DTH 160hp / 165hp | 2009-2015 |
| Opel Zafira Tourer C (P12) 2.0 CDTI | A20DTH / A20DTJ 130hp / 165hp | 2011-2019 |
| Opel Cascada (W13) 2.0 CDTI | A20DTH 165hp | 2013-2018 |
Technical Specifications
| Specification | Value |
|---|---|
| SKU | 0445110479 |
| Brand | Opel / Vauxhall / BOSCH |
| Type | Complete Injector Assembly (Bosch Common Rail (CRI2-18 solenoid)) |
| OE Number | 55577668 |
| Control Valve Core Spec | F00VC01359 |
| Nozzle Code Core Spec | DLLA152P2344 |
| Injection System | Bosch Common Rail (CRI2-18 solenoid) |
| Operating Pressure Core Spec | 1800 bar |
| Torque Spec | 28 N·m |
| Hold Down Torque | 25 N·m + 30° |
| Warranty | 12 Months |
| Emission Standard | Euro 5 |
| Engine Family | A20DTH / A20DTJ / A20DTR (2.0 CDTI Euro 5) |
| Coding Required | Yes (IMA Code) |
Installation Tips
Tools needed: Flare nut wrench (rail and injector inlet unions), Injector puller / slide hammer kit (if carbon-bonded), Injector seat cleaning brass brush set & industrial vacuum, Seat reaming tool (for restoring carbon-eroded seating faces), Calibrated torque wrench (2 N·m - 50 N·m range), Diagnostic scan tool with IMA/QR coding capability, Digital micrometer / depth gauge for copper washer check
- Depressurize Fuel Rail & Isolate Battery: Disconnect battery ground; verify via diagnostic live data that common rail pressure has dissipated below 10 bar before loosening any high-pressure pipe fittings.
- Thoroughly Clean Cylinder Head Well Recesses: Clean out all loose dirt, oil residue, and grit surrounding the A20DTH injector wells using compressed air and solvent degreaser.
- Disconnect Return Line & Cylinder Plugs: Unplug wiring harness connectors and unclip the leak-back return manifold plastic connectors carefully to avoid breaking the retaining tabs.
- Remove High-Pressure Delivery Pipes: Loosen union nuts on fuel rail and injector inlet using a 17mm flare nut wrench; immediately cap all open fittings with clean blanking caps.
- Extract Hold-Down Clamp Bolts: Loosen and discard the M6 clamp bolts. These are torque-to-yield fasteners that stretch during installation and must never be reused.
- Pull Injector Assembly Vertically: Lift injector from cylinder head bore. Use an approved puller tool on stubborn carbon-bonded units without twisting the solenoid.
- Inspect Well Base & Extract Old Copper Ring: Ensure the old sealing copper washer has not remained fused to the bottom of the cylinder head bore.
- Ream & Vacuum Injector Sealing Face: Polish and ream the cylinder head injector seat using a dedicated rotary brass seat cutter and vacuum until a flat, pristine metal surface is exposed.
- Install New OEM 1.5mm Copper Washer: Slide a brand-new 1.5mm copper crush washer onto the injector nozzle with high-temp grease to keep it centered.
- Coat Injector Body with Ceramic Grease: Apply an even, light coat of high-temp ceramic grease along the injector body barrel, keeping the nozzle tip and sealing washer strictly free of grease.
- Torque Clamp Bolts to Two-Stage Spec: Tighten new hold-down clamp bolt to 25 N·m, followed by an additional 30-degree angle turn using a calibrated torque and angle gauge.
- Refit High-Pressure Delivery Lines: Hand-start pipe union nuts to ensure clean thread engagement, then tighten to 28 N·m evenly.
- Reconnect Spill-Off Return Hose & Sensor Harness: Reconnect fuel spill-off hose clips and electrical harness plugs until an audible click confirms positive locking.
- ECU IMA Trim Code Calibration & Priming: Input the 7-character IMA code etched on the solenoid head into the corresponding cylinder slot in the ECU via diagnostic tool (OP-COM, Bosch KTS); prime fuel circuit before starting.
- CRITICAL TORQUE-TO-YIELD SEQUENCE: Hold-down clamp bolts must be torqued to 25 N·m plus a 30° angle — reusing old bolts risks bolt head shearing inside the cylinder head casting.
- MANDATORY IMA CALIBRATION: The A20DTH Euro 5 ECU relies on exact 7-digit IMA compensation values — failure to program codes causes harsh diesel combustion knock and uneven idle.
- 1800 BAR EXTREME CLEANLINESS: At 1800 bar operating pressure, microscopic particulate contamination instantly scores the F00VC01359 valve seat, causing excessive backleak and DTC P0087.
- CP4 HIGH-PRESSURE PUMP INSPECTION: If replacing injectors due to failure, inspect the fuel filter and rail for fine metal filings from CP4 pump roller wear before installing new injectors.
Frequently Asked Questions
What engine fault codes indicate a failing 0445110479 injector on an Opel Insignia 2.0 CDTI?
Frequent fault codes include P0087 (Fuel Rail/System Pressure - Too Low), P0201 through P0204 (Injector Circuit / Malfunction for Cylinders 1-4), P0299 (Turbocharger Underboost due to fueling lag), and P2263. High internal spill-off return on worn 0445110479 injectors starves rail pressure under heavy load, triggering limp-home mode.
Does Bosch injector 0445110479 require ECU coding?
Yes, Bosch injector 0445110479 requires mandatory ECU IMA coding. The A20DTH engine management system uses individual 7-digit calibration codes to adjust pilot injection quantities and maintain Euro 5 particulate emission limits. Coding is completed using diagnostic scanners such as OP-COM, Vaux-Com, Bosch KTS, or GM MDI.
Can 0445110479 be interchanged with 0445110159?
No. While 0445110159 is an older Euro 4 CRI2-16 injector (1600 bar) used on 1.9 CDTI engines, 0445110479 is a Euro 5 CRI2-18 injector operating at 1800 bar with different nozzle geometry (DLLA152P2344) and electrical characteristics. They are not interchangeable.
What is the correct tightening torque for 0445110479 hold-down clamp?
The hold-down clamp requires a two-stage tightening sequence: torque the clamp bolt to 25 N·m, then apply an additional 30° angle rotation. The high-pressure fuel pipe union nuts are torqued to 28 N·m.
Why does a failed 0445110479 injector trigger DPF regeneration issues on Insignia A20DTH?
A worn or dripping nozzle needle (DLLA152P2344) delivers incomplete fuel atomization, creating excess unburnt soot in the exhaust stream. This rapidly overloads the Diesel Particulate Filter (DPF), causing frequent active regeneration cycles, oil dilution, and premature DPF clogging.
Cross-Reference & Compatibility
Sister parts, same-platform variants, and known incompatibilities. Entries marked are reference numbers outside this catalogue — the note still applies, but there is no product page for them here.