0445110215
BOSCH 0445110215 Common Rail Injector for Mercedes Sprinter 906 / Vito W639 2.2 CDI OM646
A6460700887, 6460700987, 6460700887, A6460700787 F00VC01334 DLLA156P1368 1600 bar Product Overview
The Bosch 0445110215 is an authentic OEM common rail diesel injector tailored for Mercedes-Benz commercial and light utility vehicles powered by the OM646 2.2 CDI engine (Sprinter 906 and Vito/Viano W639). Operating at peak rail pressures up to 1600 bar on Bosch CRI2.2 architecture, this unit features the high-durability DLLA156P1368 nozzle (0433171848) and F00VC01334 control valve. It meets Euro 4 emissions requirements and directly replaces Mercedes-Benz OE references A6460700987, A6460700887, and Bosch exchange part 0986435154. Precise installation requires thorough cleaning of cylinder head blind threaded holes to avoid hydraulic lock, installation of new M6 stretch bolts with a three-stage torque sequence (7 N·m + 90° + 90°), and genuine 1.56mm copper washers.
Prevent
Compatible Injectors
Vehicle & Engine Fitment
| Vehicle | Engine | Years |
|---|---|---|
| Mercedes-Benz Sprinter II (906) 211 / 311 / 411 / 511 CDI | OM646.985 80kW/109hp | 2006-2009 |
| Mercedes-Benz Sprinter II (906) 215 / 315 / 415 / 515 CDI | OM646.986 110kW/150hp | 2006-2009 |
| Mercedes-Benz Vito / Viano (W639) 109 / 111 / 115 CDI | OM646.980 / OM646.982 2.2 CDI | 2006-2010 |
Technical Specifications
| Specification | Value |
|---|---|
| SKU | 0445110215 |
| Brand | Mercedes-Benz / BOSCH |
| Type | Complete Injector Assembly (Bosch Common Rail (CRI2.2 solenoid)) |
| OE Number | A6460700987 |
| Control Valve Core Spec | F00VC01334 |
| Nozzle Code Core Spec | DLLA156P1368 |
| Injection System | Bosch Common Rail (CRI2.2 solenoid) |
| Operating Pressure Core Spec | 1600 bar |
| Torque Spec | 30 N·m |
| Hold Down Torque | 7 N·m + 90° + 90° |
| Warranty | 12 Months |
| Emission Standard | Euro 4 |
| Engine Family | OM646 (OM646 DE22LA 2.2 CDI Euro 4) |
| 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
- Disconnect Battery & Verify Zero Fuel Pressure: Isolate negative battery terminal and verify that fuel rail pressure has collapsed using a diagnostic scanner before loosening fittings.
- Remove Air Cleaner Duct & Injector Cover: Disassemble the plastic engine acoustic covers to reveal the injector gallery; clean off any dry carbon debris thoroughly.
- Tag Wiring Plugs & Remove Leak-Off Return Clips: Label injector electrical connectors 1 to 4; gently release the fragile plastic leak-off return pipe clips with a pick tool.
- Remove High-Pressure Steel Fuel Lines: Disconnect high-pressure pipe union nuts at the common rail and injector inlets; cap all ports immediately with clean plastic stoppers.
- Back Out Single-Bolt Hold-Down Clamp: Remove the M6 clamp stretch bolt and remove the clamp fork. Discard the bolt — it is a single-use torque-to-yield fastener.
- Extract Injector Body: Withdraw the injector straight up. If coked in place ('black death'), use a dedicated mechanical or hydraulic injector puller kit without rotating the body.
- Remove Old Copper Washer from Well Base: Confirm that the old copper sealing washer has been extracted from the bottom of the bore. Never leave a double washer in place.
- Clean & Thread-Chase Blind M6 Bolt Hole: Use an M6x1.0 tap and industrial compressed air blow gun to clear all carbon, oil, and liquid from the bottom of the blind bolt hole.
- Ream Cylinder Head Injector Seat: Ream and burnish the sealing face at the bottom of the injector bore with a seat cutter tool until shiny, flat aluminum is exposed.
- Install Genuine 1.56mm Copper Crush Washer: Place a genuine Mercedes OEM 1.56mm copper washer (A6110170060) onto the nozzle shank with a touch of high-temp grease.
- Coat Body with Ceramic Anti-Seize Paste: Apply a thin coat of genuine Mercedes white ceramic paste (A001989425110) to the injector body shaft, keeping nozzle tip and washer clean.
- Torque Hold-Down Clamp in Three Stages: Fit a brand-new M6 stretch bolt and tighten in three strict stages: initial stage 7 N·m, second stage +90° turn, final stage +90° turn.
- Refit High-Pressure Delivery Pipes: Hand-tighten union nuts first, then torque injector and rail unions to 30 N·m.
- Reconnect Spill Rail, Wiring & IMA Coding: Reattach leak-off return lines and electrical plugs; enter the 6-digit IMA code from the injector head into the CDI control module.
- CRITICAL BLIND HOLE HYDRAULIC LOCK: Blowing out the M6 clamp bolt blind hole is mandatory — oil or cleaner trapped at the bottom causes hydraulic lock, resulting in loose clamps and rapid 'black death' blowout.
- STRICT THREE-STAGE TORQUE SEQUENCE: Always use new genuine Mercedes M6 stretch bolts torqued to 7 N·m + 90° + 90° — overtightening snaps the bolt; undertightening blows the copper seal.
- TWIN RELATIONSHIP WITH 0445110216: 0445110215 (Sprinter/Vito commercial map) and 0445110216 (C/E-Class sedan map) share the same hardware, but their factory IMA calibration maps match different vehicle dynamics.
- CERAMIC GREASE APPLICATION: Use only white ceramic anti-seize paste — never use copper grease or graphite on aluminum Mercedes CDI cylinder heads.
Frequently Asked Questions
What is the difference between Bosch 0445110215 and 0445110216?
Both 0445110215 and 0445110216 are Bosch CRI2.2 common rail injectors built for the Mercedes OM646 2.2 CDI engine sharing the DLLA156P1368 nozzle and F00VC01334 valve. However, 0445110215 is factory-calibrated for Sprinter and Vito commercial van duty cycles (OM646.985/986), while 0445110216 is calibrated for passenger car models (C200/C220 CDI W204, E200/E220 CDI W211). While physically interchangeable, the ECU must be reprogrammed with the correct unit's IMA code.
What is 'Black Death' on Mercedes OM646 engines and how does 0445110215 installation prevent it?
'Black Death' refers to the rock-hard black carbon crust that encases injectors when the copper sealing washer fails, allowing high-pressure combustion gas to blow past the injector well. Prevention requires three mandatory steps: reaming the injector seat to flat metal, installing a genuine 1.56mm copper washer, cleaning out the M6 blind hole, and tightening a new stretch bolt to 7 N·m + 90° + 90°.
What is the tightening torque for 0445110215 hold-down clamp?
The single M6 clamp stretch bolt must be tightened in three stages: 7 N·m initial torque, followed by a 90-degree angle rotation, and a second 90-degree angle rotation (7 N·m + 90° + 90°). High-pressure fuel line union nuts are torqued to 30 N·m.
Does Bosch 0445110215 require ECU coding on Mercedes Sprinter?
Yes, cylinder-specific 6-digit IMA coding is mandatory. Programming this value into the CDI ECU via Mercedes Star Diagnosis (Xentry), Autel MaxiSys, or Bosch KTS calibrates fuel flow deviations across rail pressure bands to maintain smooth idle and low emissions.
What washer thickness is required for 0445110215 on OM646?
The factory specification copper washer is 1.56mm (Mercedes part number A6110170060). Never install a non-standard 2.0mm or 1.0mm washer, as altered nozzle protrusion distorts the combustion spray bowl focus.
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.