0445110263 Fuel Injector – Bosch-Compatible Common Rail Injector for Mercedes-Benz OM 646.98 Diesel Engine
The 0445110263 common rail solenoid injector (Bosch compatible) is a precision fuel injection component specifically calibrated for the Mercedes-Benz OM 646.98 engine – a 2.2L CDI powerplant found in numerous C-Class, E-Class, and Sprinter vans. Whether you are restoring a passenger car or maintaining a commercial fleet, this injector delivers factory‑correct spray patterns, reduced diesel knock, and improved fuel economy. Below we examine its structural advantages, vehicle fitment, common failure signs, installation best practices, and why Rsolid engine parts is your ideal supplier.
1. Structural Advantages of the 0445110263 Injector
The 0445110263 belongs to Bosch’s CRI2‑20 solenoid injector family, offering several engineering benefits tailored to the OM 646 platform:
High‑speed magnetic solenoid – Achieves opening times < 0.2 ms at 1,600 bar, enabling multiple pilot injections per cycle. This significantly reduces the characteristic “diesel clatter” of the OM 646 engine and lowers NOx emissions.
Hardened stainless steel body – Withstands rail pressures up to 1,800 bar (typical OM 646 system operates at 1,600 bar) and resists corrosion from moisture and fuel impurities.
6‑hole micro‑sac nozzle – Laser‑drilled orifices produce an extremely fine, homogeneous fuel spray that matches the OM 646’s swirl‑intake combustion chamber, improving cold starts and reducing soot formation.
Balanced hydraulic servo system – Minimises internal fuel leakage and maintains consistent injection quantity across all four cylinders, which is critical for smooth idle and balanced power delivery.
Plug‑and‑play electrical connector – Matches OEM pin assignment and coil resistance (0.23–0.27 Ω), allowing direct ECU connection without modifications.
These features translate into quieter operation, better throttle response, and extended DPF (Diesel Particulate Filter) life when using ULSD (Ultra Low Sulfur Diesel).
2. Compatible Engine & Vehicle Models – OM 646.98
The 0445110263 injector is specifically designed for the Mercedes-Benz OM 646.98 diesel engine – a 2.2L (2,148 cc) common rail CDI unit. Verified applications include:
| Engine Code | Displacement | Fuel System | Power Outputs (typical) |
|---|
| OM 646.98 (incl. OM 646.981, .982, .983) | 2,148 cc | Bosch CP3 (1,600 bar) | 102 kW (136 hp) – 125 kW (170 hp) |
Detailed vehicle list (Mercedes-Benz models):
| Model | Chassis / Series | Years | Engine Code | Notes |
|---|
| C-Class | W203 (C200 CDI, C220 CDI) | 2003–2007 | OM 646.96 / .98 | 2.2L CDI |
| C-Class | W204 (C200 CDI, C220 CDI) | 2007–2010 | OM 646.98 | Pre‑facelift |
| E-Class | W211 (E200 CDI, E220 CDI) | 2003–2009 | OM 646.98 | 2.2L CDI |
| Sprinter | W906 (Van, Minibus) | 2006–2016 | OM 646.98 | 2.2L CDI (208/308/408/509 CDI) |
| Viano / Vito | W639 | 2004–2014 | OM 646.98 | 2.2L CDI |
| CLK | W209 (CLK 220 CDI) | 2004–2009 | OM 646.98 | 2.2L CDI |
Note: Always verify your original injector part number – look for 0445110263 or Mercedes OEM numbers A6460700887, A6460700987, A6460701187. Some OM 646 engines use injector 0445110245 or 0445110272 – check fitment carefully.
3. Common Failure Symptoms & Installation Replacement Advice
The OM 646 engine is known for injector wear, especially after 150,000–200,000 km. Recognising early symptoms can prevent costly DPF, EGR, or turbocharger issues.
Typical failure symptoms of a failing 0445110263 injector:
Rough idle, especially when warm – The engine shakes at traffic lights; cylinder balance values > ±2.0 mg/stroke on diagnostic tool (e.g., STAR Diagnostic).
Excessive black smoke under acceleration – Over‑fueling due to a worn needle or stuck solenoid.
White smoke on cold start – Poor atomisation from a clogged or worn nozzle tip; may clear after warm-up.
Hard starting or long cranking – Rail pressure cannot build due to internal leakage (return flow > 30 ml/min at idle).
Increased fuel consumption – Fuel is pumped but not properly injected; return fuel volume high.
Engine oil dilution – Diesel fuel leaking past the injector tip into the cylinder, then past piston rings into the oil. Check for rising oil level and diesel smell – dangerous.
Frequent DPF regeneration – Excess soot from poor combustion blocks the DPF rapidly, causing “DPF full” warnings.
P0201–P0204 injector circuit codes – Solenoid coil electrical failure (intermittent open or short).
Black smoke on overrun (deceleration) – Injector needle not closing fully due to contamination.
Installation & replacement best practices for OM 646.98 engine:
Always replace all sealing components – Use a new copper sealing washer (14mm ID) and upper O‑ring (Bosch seal kit 2 418 227 053). Never reuse old seals – they cause combustion blow‑by.
Clean the injector bore thoroughly – Use a 14mm injector seat reamer to remove carbon deposits from the cylinder head. Even a thin carbon layer prevents proper sealing.
Lubricate new O‑rings with clean diesel fuel – Never use grease or engine oil, which can block the fine nozzle passages.
Torque injector hold‑down clamp precisely – For OM 646: typical 25 Nm + 90° (use a new clamp bolt each time). Over‑torquing distorts the injector body; under‑torquing causes leakage and combustion gas ingress.
Replace fuel filter – Contaminated fuel is the #1 cause of new injector failure. Install a genuine Mercedes fuel filter (A 611 092 03 01 or equivalent).
Prime the fuel system – Use a hand primer (located on the fuel filter housing) or cycle ignition on/off to run the lift pump (if equipped). Cranking without priming damages new injectors.
Code the injector using a diagnostic tool – The 0445110263 has a 10‑character IMA (Injector Matching Adjustment) code on its top label. Using Mercedes STAR Diagnostic, Autel MaxiSys, Launch X431, or other professional scanner, enter the code into the ECU. Without coding, the engine will run rough and trigger DTCs.
Perform leak‑off test after installation – Run engine at idle for 2 minutes, then measure return fuel from each injector (use graduated cylinders). All should be below 20 ml/min and within 5 ml/min of each other.
Reset adaptation values – After coding, perform “Injector Quantity Adaptation” and “Fuel Pressure Adaptation” via diagnostic software. For STAR Diagnostic, run “Teach-in of injectors” routine.
Road test – Drive for 10–15 minutes to allow ECU to fine‑tune adaptations.
4. Why Choose Rsolid Engine Parts as Your Supplier?
At Rsolid engine parts, we specialise in high‑quality diesel fuel injection components. Here’s why thousands of workshops and fleet owners trust us:
100% test‑bench verified – Every 0445110263 injector is calibrated on a professional common rail test bench (up to 2,000 bar) with flow balance guaranteed within ±2%.
Bosch‑compatible, OE fitment – Direct replacement for Mercedes A6460700887 and equivalents; matches all dimensions, solenoid resistance, and spray angles.
New build, not remanufactured – All units are newly manufactured to Bosch specifications, not reconditioned or repaired.
Competitive wholesale pricing – Ideal for volume buyers, repair shops, and individual owners.
Fast global shipping – Stock available from our warehouses in Asia, Europe, and North America.
Expert technical support – Our team helps with IMA coding, torque specifications, and troubleshooting for OM 646 engines.
12‑month warranty – Against manufacturing defects and premature wear.
📧 Contact us for a quote or technical assistance:
✉️ Email: amy@rinjector.com
🌐 Website: www.rinjector.com
