0445110091
BOSCH 0445110091 for D4CB H-1/Starex - OEM 338004A000
33800-4A000 33800-4A100 33800-4A150 33800-4A160 33800-4A170 F00VC01033 DLLA156P1114 1600 bar peak rail Product 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.
Compatible Injectors
Vehicle & Engine Fitment
| Vehicle | Engine | Years |
|---|---|---|
| Hyundai H-1 / Starex / Grand Starex | D4CB 2.5L CRDi 16V (100-125 kW) | 2001-2011 |
| Hyundai Porter / H-100 | D4CB 2.5L CRDi | 2003-2015 |
| Kia Sorento (JC/BL) | D4CB 2.5L CRDi 16V | 2002-2009 |
| Hyundai iLoad / i800 | D4CB 2.5L CRDi | 2007-2017 |
| Kia Bongo 3 / K2500 / K2700 | D4CB 2.5L CRDi | 2005-2020 |
Technical Specifications
| Specification | Value |
|---|---|
| SKU | 0445110091 |
| Brand | BOSCH |
| Type | Complete Injector Assembly (CRI2 solenoid) |
| OE Number | 33800-4A000 (Hyundai primary) |
| Nozzle Code Core Spec | DLLA156P1114 |
| Nozzle Stamping Core Spec | 0433111114 |
| Control Valve Core Spec | F00VC01033 |
| Injection System | Bosch Common Rail (CRI2 solenoid, 0445110 series) |
| Operating Pressure Core Spec | 1600 bar peak rail |
| 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 |
| Kompatible Schwester-SKUs (same F00VC01033, NOT interchangeable) | 0445110092, 0445110185, 0445110186, 0445110279, 0445110730 |
Installation Tips
- With engine cold, disconnect battery negative terminal. Remove fuel pump fuse (located in the engine bay fuse box - consult owner's manual for exact location). Crank engine 3 times without starting to release residual rail pressure. Wait 5 minutes before opening the HP fuel circuit. Never crack HP lines while the rail is pressurised - the D4CB operates at up to 1600 bar.
- Label and disconnect the 2-pin electrical connector (note orientation - the D4CB connector is weatherpack-style, water-resistant but handle carefully). Remove HP fuel lines using 14 mm flare-nut wrenches; label each line for cylinder position. Remove the injector clamp bolts (usually 2 per injector on the D4CB head). Gently rock the old injector free - use an injector puller tool if seized. Do NOT use a screwdriver to pry - risk of damaging the bore.
- Clean the injector bore with a bore brush (19-21 mm); remove all carbon deposits and old seal material. Inspect the bore for cracks or corrosion - if damaged, machine repair may be required before fitting the new injector. Fit new copper sealing washers (top and bottom) and new O-rings on the new 0445110091. Lubricate O-rings with clean engine oil only - do NOT use diesel fuel as a lubricant.
- Lower the new 0445110091 vertically into the bore (tilt angle will cause poor sealing at the copper washer). Install the injector clamp and hand-tighten bolts. Torque in two stages: first pass 5 N·m, final pass 12-16 N·m (Autodata spec for D4CB). Overtightening will crack the injector body - under-tightening causes fuel leaks. Reconnect HP lines at 25 N·m.
- Reconnect the electrical connector securely (ensure it clicks into place - D4CB connectors are prone to water ingress). Reinstall fuel pump fuse. Prime the system: key ON for 5 seconds, OFF for 10 seconds, repeat 3 times. Start the engine and check for leaks at all connections. Idle should be smooth after 30 seconds - if rough, check for air in the HP lines and bleed if necessary.
- Connect Hyundai GDS Mobile, Kia GDS, or Bosch KTS diagnostic tool. Navigate to: Injector > IMA coding > Reset. Enter the VIN and select cylinder position (1-4). Programme the new 0445110091 IMA calibration code from the injector label. Run a balance-rate test to verify equal fuel delivery across all cylinders. Clear all stored fault codes P0201-P0204. Without IMA coding, the D4CB enters limp mode with reduced power.
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.