0445110115
BOSCH 0445110115 for Mercedes A-Class W168 1.7 CDI OM668
A6680700987, A6680701287, A6680780223F00VC01024DLLA156P11551350 bar peak rail pressureProduct Overview
The BOSCH 0445110115 is a complete injector assembly for the Mercedes-Benz OM668 engine family - the first-generation CRI (Common Rail Injection) solenoid-actuated fuel system used in the A-Class W168 (A 160 CDI / A 170 CDI, 1998-2004). The F00VC01024 control valve operates via a precision solenoid with a 3-6 micron clearance, regulating fuel flow to support multi-stage injection at up to 1350 bar peak rail pressure. The OE nozzle DLLA156P1155 (internal Bosch code 0433175342) is a precision spray nozzle designed for the OM668 combustion chamber. The OM668 engine family is known for its sensitivity to injector balance - each injector carries a unique IMA calibration code that must be registered in the ECU after installation. Compatible with A 160 CDI (44/55 kW) and A 170 CDI (66/70 kW) variants. Sister SKUs 0445110116 (Bosch exchange), 0445110097, 0445110098 (sister CRI variants) share F00VC01024 valve and DLLA156P1155 nozzle but carry unique IMA codes - NOT interchangeable without ECU re-coding.
Verify engine code OM668.942 on the block and OE number A6680700987 (A 160 CDI 44/55 kW) or A6680701287 (A 170 CDI 66/70 kW) on the injector body before ordering.
Vehicle & Engine Fitment
| Vehicle | Engine | Years |
|---|---|---|
| Mercedes-Benz A-Class W168 A 160 CDI | OM668 / OM668.940 / OM668.941 / OM668.942 | 1998-2004 |
| Mercedes-Benz A-Class W168 A 170 CDI | OM668 / OM668.940 / OM668.941 / OM668.942 | 1998-2004 |
Technical Specifications
| Specification | Value |
|---|---|
| OEM Number | A6680700987, A6680701287, A6680780223 |
| Engine Family | OM668.940 |
| Control ValveCore Spec | 🔗 Shared Valve (2 assemblies):0445110116 |
| Nozzle CodeCore Spec | |
| Internal Nozzle P/NCore Spec | |
| Injection System | Common Rail Diesel (CRI) |
| Emission Standard | Euro 3 |
| Material | High Speed Steel |
| Warranty | 12 months |
| Net Weight | 600 g |
| Operating PressureCore Spec | |
| Magnet Assembly | F00VC30053 |
| Seal Ring Kit | F00VC99002 |
Installation Tips
- Depressurise fuel system: remove fuel pump fuse, crank engine until it stalls, disconnect battery negative.
- Remove engine cover; disconnect injector electrical connectors - tag each with cylinder number (1-4).
- Remove HP fuel rail: use correct flare nut wrenches on banjo bolts.
- Remove the single central hold-down bolt per injector (OM668 uses ONE bolt, not two).
- Extract old injector; inspect bore for carbon deposits or corrosion.
- Check solenoid resistance with multimeter: normal 0.5-2.0 Ohm cold; open circuit or > 3 Ohm = replace.
- Fit new copper washer (top) and O-ring (bottom) on new 0445110115.
- Apply thread sealant (Loctite 243) to hold-down bolt threads.
- Insert injector straight; install clamp; hand-tighten bolt.
- Torque hold-down bolt: Stage 1 = 7 N·m; Stage 2 = 90° angle turn (approx. 14-16 N·m final, always use a new stretch bolt). High-pressure line union nuts: 25-30 N·m.
- WARNING Never exceed 25 N·m static on the M6 clamp bolt - over-torque strips the aluminum cylinder head threads.
- Reconnect HP rail banjo bolts, then injector harness; ensure connector seals are seated.
- Prime fuel system: hand pump 3x, crank 5 sec, check for leaks at banjo joints.
- With Star Diagnostic (SDS): Motor Electronics -> Injectors -> Code Cylinders -> enter 4-digit IMA code.
- Clear fault codes; road test 10-15 minutes; monitor for rough idle, MIL, or black smoke.
Frequently Asked Questions
What P-codes does a faulty 0445110115 trigger on the OM668 engine?
Common fault codes: P0201-P0204 (cylinder injector circuit faults - open/short circuit in solenoid wiring), P0300-P0304 (random/multi-cylinder misfire - fuel metering error from worn valve), and P0562/P0563 (system voltage low/high - often caused by corroded injector harness connector pins from fuel weepage). On the OM668, the injector harness connectors are prone to moisture ingress due to their low position in the engine bay. Diagnosis: measure solenoid resistance (typical 0.5-2.0 Ohm) with engine cold; if open circuit or > 3 Ohm, replace the injector.
How do I confirm 0445110115 is the right part for my Mercedes A 170 CDI W168?
Three verification steps: (1) Engine code - look for 'OM 668.942' stamped on the engine block near the injection pump; (2) OE part number - Bosch 0445110115 stamped on the injector body near the electrical connector; (3) Connector type - the OM668 uses a 2-pin push-fit connector (black, 2-way). Cross-reference: A6680700987 = A 160 CDI (44/55 kW), A6680701287 = A 170 CDI (66/70 kW). The correct Bosch part for both is 0445110115.
0445110115 vs 0445110116 - what is the difference?
Both share F00VC01024 valve and nozzle 0433175342. 0445110115 is the primary OE Bosch part number; 0445110116 is the Bosch exchange/service part number for the same physical injector. They are interchangeable - use whichever is cheaper or more available.
What is the difference between 0445110115 and 0445110097 / 0445110098?
0445110097 and 0445110098 share the same F00VC01024 valve group and are likely the same physical injector under different exchange codes. Each has a unique IMA calibration code - always match the exact 0445110115 stamped on your original injector, not just the valve code. Wrong IMA causes rough idle and P0300.
What torque spec should I use for injector hold-down bolts on OM668?
Mercedes-Benz OM668 procedure: (1) Apply thread sealant to hold-down bolts; (2) Pre-torque to 7 N·m (criss-cross); (3) Final stage: turn a further 90°(torque-to-yield - always use a new stretch bolt; approx. 14-16 N·m equivalent). WARNING Key error: the OM668 uses a SINGLE central hold-down bolt per injector - over-tightening (> 25 N·m) can crack the clamp tab. After installation, use Star Diagnostic to code the new injector into the ECU.
Does the 0445110115 require ECU coding after installation on the W168?
Yes - mandatory on all OM668 engines. Use Star Diagnostic (SDS), HHT, or compatible after-market scanner (e.g., Autel Maxisys with Mercedes DAS). Navigate to Motor Electronics -> Injectors -> Code Cylinders -> enter the 4-digit IMA code from the new injector label. Without coding, the ECU defaults to a generic map causing rough idle and increased fuel consumption. Workshop time: 30-60 minutes including road test.
What is the warranty on 0445110115 and what voids it?
Standard warranty: 12 months from invoice date. Covers: solenoid coil open-circuit, control valve failure, nozzle blockage from manufacturing defect. Voided by: (1) installation damage from over-torquing the single hold-down bolt; (2) fuel contamination; (3) missing ECU coding causing over-fuelling; (4) use of bio-diesel blends above B7. Keep the Star Diagnostic printout showing successful injector coding as warranty evidence.
Can I use 0445110115 in a later Mercedes CDI engine (OM646 / OM651)?
No - 0445110115 is specific to OM668 (A-Class W168, 1998-2004). The later OM646 (2003-2006) and OM651 (2008+) engines use different injector designs with different control valve codes and ECU protocols (MED17 vs EDC16). Installing an OM668 injector in an OM646/651 will cause permanent MIL and possible engine damage. Verify engine code on the block before ordering.
0445110115 vs non-OEM aftermarket injectors - worth paying more?
For the OM668, genuine Bosch or quality remanufactured units are strongly recommended. The A-Class is sensitive to injector balance - mismatched injectors cause cylinder-to-cylinder variation that the ECU cannot fully compensate. Aftermarket injectors for this early CRI system are notorious for inconsistent spray pattern and premature valve wear. Budget option: use a Bosch Exchange reman (core exchange programme) rather than a third-party aftermarket.
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.
Cross-Reference & Compatibility
Sister parts, same-platform variants, and known incompatibilities.
Technical Diagnostic & Service Protocols
Authoritative field procedures, diagnostic testing thresholds, and service SOPs for this assembly.