Bosch 0445116027 Diesel Injector

On the 3.0 CDI platform, a failing Bosch 0445116027 injector typically presents as: burnt-diesel smell with black tar-like build-up around an injector (the documented 'black death'); chuffing or hissing from the injector area at idle; hard starting, particularly warm starts; rough idle or misfire-like running; smoke and reduced power when a leak is advanced.

When two or more of these appear together, suspect the injector before peripheral systems — a comparative leak-off test and live-data cylinder-balance review will isolate the failed unit without tear-down.

The documented failure modes on this platform are: injector copper seal / seat failure letting combustion gas carbonise around the injector base; piezo injector internal faults degrading atomisation and drifting correction values out of range; injectors carboning into the bore when seal leaks are left unrepaired, making removal difficult.

Internal wear cannot be repaired in situ — once delivery drifts outside calibration, remanufacture or replacement is the reliable fix.

Inspect around every injector for black crust before diagnosis — the failure is often the seal and seat, not the injector body. Clean or recut the injector seat before fitting a replacement; always use a new copper sealing washer. Check injector correction values across all six cylinders — an outlier identifies the failing unit. Address seal leaks early: a long-running leak can seize the injector into the head.

Never condemn a common-rail injector on a fault code alone — codes identify the circuit or cylinder, while leak-off volumes and correction values identify the component.

Each remanufactured 0445116027 is fully stripped, ultrasonically cleaned and inspected; worn components are replaced with OE-grade parts. The rebuilt unit is then calibrated on a common-rail test bench against the manufacturer's specification sheet — delivery, back-leak and response are all verified before the injector is sealed and despatched with its calibration data on file.

Every unit carries a 12-month parts warranty and free UK delivery.

The 0445116027 trusted family covers 5 verified vehicle fitments across 1 make: Mercedes-Benz. Every fitment listed on this page is registry-verified — no scraped or assumed applications.

0445116027 supersedes or cross-references 11 further OE numbers, including 0445116028, 0445116025, 0445116026, 0986435406, 0986435404, 6420701287, 642070128780 and A6420701287. Always match the reference etched on your failed unit's body — cross-references within a family are verified equivalents, but etched numbers remain the source of truth.