0445116081 — Technical Research
Bosch piezo common-rail injector for the Volvo 2.4 five-cylinder D5/D4 (D5244T) engine. Bosch exchange 0986435393; Volvo OE 30777226/31272690/36002662; Bosch alternate 0445116016. Piezo and solenoid injectors are not interchangeable - match the type and exact OE. Replacements are coded to the ECU. Failures are driven by poor fuel filtration, contamination and back-leakage. Key symptoms: Rough idle / vibration; Hard starting; Loss of power / limp mode; Black smoke. Common failure modes: Internal wear / high back-leakage; Piezo stack degradation; Nozzle coking.
Bosch 0445116081 2.4 D5/D4 (D5244T) Piezo Common Rail Injector (Volvo)
Bosch piezo common-rail injector for the Volvo 2.4 five-cylinder D5/D4 (D5244T) engine. Bosch exchange 0986435393; Volvo OE 30777226/31272690/36002662; Bosch alternate 0445116016. Piezo and solenoid injectors are not interchangeable - match the type and exact OE. Replacements are coded to the ECU. Failures are driven by poor fuel filtration, contamination and back-leakage. Key symptoms: Rough idle / vibration; Hard starting; Loss of power / limp mode; Black smoke. Common failure modes: Internal wear / high back-leakage; Piezo stack degradation; Nozzle coking.
A leaking injector unbalances cylinder fuelling on the 2.4 D5.
Excess back-leakage drops cranking rail pressure.
Out-of-range delivery or rail-pressure deviation cuts power.
Poor atomisation over-fuels the cylinder.
Cylinder-specific injector or fuel-metering codes.
- InstallationCode the injector value to the correct cylinder with VIDA/diagnostic before road test.
- InstallationRenew the copper combustion washer and leak-off seals; torque the clamp to spec.
- WarningPiezo and solenoid injectors are not interchangeable - confirm 0445116081 (piezo) and the exact OE before ordering.
- MisdiagnosisRead live back-leakage / cylinder-balance data to find the weak cylinder before removal.
- TestingBench-test on a piezo-capable CR tester; verify response and spray pattern before refit.
What is Bosch injector 0445116081?+
A Bosch piezo common-rail diesel injector for the Volvo 2.4 five-cylinder D5/D4 (D5244T) engine. Bosch exchange 0986435393; Volvo OE 30777226/31272690/36002662.
Which vehicles use 0445116081?+
Volvo S60 II, V60, XC60, XC70/V70 III and S80 II 2.4 D5/D4 (D5244T).
Is it solenoid or piezo?+
It is a Bosch piezo common-rail injector - do not substitute a solenoid injector.
Does 0445116081 need coding?+
Yes - code the injector value to the correct cylinder with Volvo VIDA when fitting.
What are the OE part numbers?+
Volvo 30777226, 31272690 and 36002662 reference Bosch 0445116081; the Bosch exchange number is 0986435393 and 0445116016 is an alternate.
Can I mix it with 0445116016?+
0445116016 is an alternate within the same family - fit a matched set and confirm the exact OE for your engine variant.
What are the symptoms of failure?+
Rough idle, vibration, hard starting, black smoke, power loss/limp mode and an EML.
Why does my Volvo D5 run rough?+
A worn or leaking injector unbalances fuelling; read live cylinder-balance data and bench-test the suspect cylinder.
What causes these injectors to fail?+
Poor fuel filtration, contamination and back-leakage wear plus piezo-stack ageing - fix the cause first.
Does a remanufactured 0445116081 perform like new?+
A properly remanufactured injector is bench-tested and recalibrated on a piezo-capable tester, then coded on fitment.