0445110311

1. Depressurise and disconnect: Remove fuel pump fuse, crank engine 5 seconds to release rail pressure, then disconnect battery negative terminal. NEVER crack HP lines with the rail pressurised.
2. 2-wrench procedure (CRITICAL): Use a 15 mm wrench to hold the F00VC01364 solenoid body and a 17 mm wrench to tighten the high-pressure line nut — applying force directly to the solenoid twists the valve assembly and causes a permanent no-start fault. This applies to all Bosch CRIN2/CRI2 injectors on the DV6 1.6 HDi platform.
3. Injector hold-down torque (snap-on ring style): The 0445110311 uses a snap-on retaining ring, NOT a clamp bolt. First fit the snap-on ring into the cylinder head bore using Bosch snap-on pliers (Bosch 0 986 610 075 or equivalent). Then insert the injector until the snap engages. Cross-pattern tightening does not apply here — the snap is single-action.
4. Hold-down ring / clamp final torque: 4 N·m + 65° (approximately 9-10 N·m equivalent if your DV6 variant uses a bolt-down clamp instead of the snap-on ring, verify against your engine code: 9HT/9HX = bolt-down clamp; 9HV = snap-on ring on earlier production). When in doubt, always refer to the PSA workshop manual for your specific model year.
5. HP line torque: 25-30 N·m with 15 mm (solenoid side) + 17 mm (line side) flare nut wrenches. Do NOT use an impact wrench on either side.
6. Replace ALL seals: New copper washer (HP side) and new O-rings (return side) on every reinstall — reuse is the #1 cause of post-install leaks on DV6. Lubricate O-rings with clean engine oil, NOT silicone grease.
7. Clean the injector bore with a 17-19 mm reamer before insertion. Carbon deposits on the bore seat will prevent the snap-on ring from seating fully and cause combustion gas leakage (P0401 / P0402 false codes are a common symptom).
8. Prime and start: Hand pump the low-pressure circuit 3x before cranking. Then crank engine WITHOUT throttle for 5-10 seconds to clear air from the high-pressure rail. Start and idle at 1500 rpm for 5 minutes — check all HP joints for leaks.
9. IMA coding (CRITICAL for 9HX): The 9HX variant requires 4-digit IMA (Injection Quantity Adjustment) coding via Bosch KTS 590 or PSA Lexia/Planet. Enter the code printed on the new injector body. Failure to code results in P0201-P0204 (cylinder-specific injector circuit) and P0300 (random misfire) within 5-10 minutes of first start.
10. Post-install OBD scan: Codes to watch after a DV6 injector swap: P0201 / P0202 / P0203 / P0204 (cylinder-specific circuit fault), P0300 / P0301 / P0302 / P0303 / P0304 (cylinder misfire), P2146 (injector group A supply voltage), P0401 (EGR flow insufficient — false positive if bore leak), P2299 (brake pedal position — unrelated, clear and ignore). Persistent codes after 3 drive cycles = real fault, diagnose before clearing.
11. Injector balance verification: Use Bosch KTS or PSA Lexia to run the cylinder cut-out / contribution test. Deviation between cylinders must be within ±3 percent. Out-of-spec deviation indicates a defective replacement injector (rare) or air ingestion at the feed tube (loose 1.25-1.5 N·m connector nut).
12. Hot re-torque check: After a 30-minute road test, let the engine cool 15 minutes and re-torque the HP line nuts to 25-30 N·m. Thermal cycling can relax clamping force by 5-10 percent.

Common diagnostic trouble codes (DTCs) triggered when this common rail injector experiences wear, circuit faults, or calibration drift: