O2 sensor ASTON MARTIN V8 VANTAGE 2010 Workshop Manual

Exhaust Overview
Exhaust System (09.00)9-1-2 Workshop Manual Issue 5, January 2010
Exhaust System (09.00)
Exhaust Overview
The exhaust system consists of two four -branch manifolds, two catalytic converte rs, four oxygen sensors and a single
variable flow silencer assembly.
Exhaust gasses flow from the exhaust manifolds, through the catalysts and on to the rear silencer assembly.
• Two engine management oxygen sensors are mounted before the catalysts. • Two catalyst monitor oxygen sensors are mounted in
the catalysts between the primary and secondary
catalyst brick.
09-01-001
Four Branch Manifolds Catalytic Converter Flow Silencer
Oxygen Sensors

Silencer Assembly (09.01)
Exhaust (09.00)
Issue 5, January 2010 Workshop Manual 9-1-3
Exhaust (09.00)
Silencer Assembly (09.01)
Variable Flow Silencer Assembly
The rear silencer assembly has a variable fl ow path controlled by two bypass valves.
The system is intended to enhance top end performance in mo tor sport applications and will not operate in most normal
driving conditions.
By directing exhaust gasses through a modified path at high vehicle speeds, exhaust back pressure is reduced and top end
performance is enhanced.
As engine speed increase from idle, the bypass valve is open until the engine speed is 1500 rpm.
From 1500 rpm to 3000 rpm, the valve is closed
Above 3000 rpm the bypass valves state is load dependent (fully open at higher loads).
Maintenance
LH Catalyst & Pipe Assembly-Renew
Removal
1. Raise vehicle on ramp.
2. Remove rear exhaust silencer (refer to Workshop Manual procedure 09.00.KA Muffler & Bypass Valve
Assembly - Remove for Access & Refit).
3. Disconnect multiplugs (x2), HEGO sensors.
4. Release sensor lead from clip on heatshield.
5. Secure sufficient lengths of string to HEGO sensor multiplugs for assembly purposes.
6. Loosen LH and RH clamp nuts , catalysts to centre pipe.
7. Remove nuts (x3), catalyst to exhaust manifold.
8. With assistance, manoeuvre exhaust centre pipe assembly rearwards to release from catalysts.
9. With assistance, release and support weight of LH catalyst from exhaust manifold.
10. Manoeuvre HEGO sensor le ads and remove cable tie.
Release HEGO sensor leads from behind heat shield.
Secure cable tie. Remove string from HEGO multiplugs.
11. Remove catalyst assembly.
12. Remove and discard gasket. 13. Remove HEGO sensor
s (x2) from catalyst.
Installation
1. Clean catalyst, mating joint faces and HEGO sensors..
2. Install and tighten HEGO sensors (x2) to catalyst.
3. Apply proprietary exhaust se alant around pipe joints.
4. Install new gasket to exhaust manifold flange.
5. With assistance, position cata lyst, secure string (x2) to
HEGO multiplugs, feed sensor leads behind heat shield.
Install catalyst to exhaust manifold.
6. Install and torque tighten nuts (x3), catalyst to exhaust manifold.
7. Align centre pipe asembly to catalyst, torque tighten
clamp nuts.
8. Remove string (x2), conne ct multiplugs (x2), HEGO
sensors.
9. Secure sensor lead in clip on heatshield.
10. Install rear exhaust silencer (refer to Workshop Manual procedure 09.00.KA Muffler & Bypass Valve Assembly -
Remove for Access & Refit).
11. Lower vehicle on ramp.
RH Catalyst & Pipe Assembly-Renew
Repair Operation Time (ROT)
Repair Operation Time (ROT)

Silencer Assembly (09.01)
Exhaust (09.00)9-1-4 Workshop Manual Issue 5, January 2010
Removal
1. Raise vehicle on ramp.
2. Remove rear exhaust silencer (refer to Workshop Manual procedure 09.00.KA Muffler & Bypass Valve
Assembly - Remove for Access & Refit).
3. Disconnect multiplugs (x2), HEGO sensors.
4. Release sensor lead from clip on heatshield.
5. Secure sufficient lengths of string to HEGO sensor multiplugs for assembly purposes.
6. Loosen LH and RH clamp nuts , catalysts to centre pipe.
7. With assistance, manoeuvre exhaust centre pipe assembly rearwards to release from catalysts.
8. Remove nuts (x3), catalyst to exhaust manifold.
9. With assistance, release and support weight of RH catalyst from exhaust manifold.
10. Manoeuvre HEGO sensor leads and remove cable tie. Release HEGO sensor leads from behind heat shield.
Remove string from HEGO multiplugs.
11. Remove catalyst assembly.
12. Remove and discard gasket.
13. Remove HEGO sensors (x2) from catalyst.
Installation
1. Clean catalyst, mating joint faces and HEGO sensors..
2. Install and tighten HEGO sensors (x2) to catalyst.
3. Apply proprietary exhaust sealant around pipe joints.
4. Install new gasket to exhaust manifold flange.
5. With assistance, position catal yst, secure string (x2) to
HEGO multiplugs, feed sensor leads behind heat shield.
Secue cable tie. Install catalyst to exhaust manifold.
6. Install and torque tighten nuts (x3), catalyst to exhaust manifold.
7. Align centre pipe asembly to catalyst, torque tighten
clamp nuts.
8. Remove string (x2), connect multiplugs (x2), HEGO sensors.
9. Secure sensor lead in clip on heatshield.
10. Install rear exhaus t silencer (refer to Workshop Manual
procedure 09.00.KA Muffler & Bypass Valve Assembly -
Remove for Access & Refit).
11. Lower vehicle on ramp.
LH Exhaust Manifold-Renew-Roadster
Only
Removal
1. Disconnect vehicle battery.
2. Raise vehicle on ramp. 3. Remove heatshield deflec
tor, front floor (refer to
Workshop Manual procedure 09.04.AA Heatshield -
Front Floor - Renew).
4. Remove LH front wheel arch liner (refer to Workshop Manual procedure 01.02.FB Wheel Arch Liner - Front -
LH - Renew).
5. Remove nuts (x8), securing manifold to cylinder head.
6. Remove exhaust manifold, remove and discard gasket.
Installation
1. Clean manifold and mating face on engine. Install new gasket to engine.
2. Install manfold to engine.
3. Install nuts (x8) securing manifold to cylinder head
(torque).
4. Install LH front wheel arch liner (refer to Workshop Manual procedure 01.02.FB Wheel Arch Liner - Front -
LH - Renew).
5. Install heatshield deflector, front floor (refer to Workshop Manual procedure 09.04.AA Heatshield -
Front Floor - Renew).
6. Lower vehicle on ramp.
7. Connect vehicle battery.
Heated Exhaust Gas Oxygen (HEGO)
Sensor - Remove and Install
Removal
1. Raise the vehicle and make it safe.
2. Release the two electrical connnectors for the Heated Exhaust Gas Oxygen (HEGO) sensor from the bracket.
3. Disconnect the two electrical connnectors from the HEGO sensor.
4. Move the two wiring harnesses for the HEGO sensor away.
5. Remove the two bolts that attach the bracket to the engine.
6. Remove the bracket.
7. Remove the two bolts that attach the heat shield to the torque tube.
8. Move the heat shield away.
Repair Operation Time (ROT)
Repair Operation Time (ROT)
ItemCode
Heated Exhaust Gas Oxygen (HEGO)
Sensor - Remove and Install 09.00.DB
WAR NI NG
THE EXHAUST SYSTEM WILL BE VERY HOT AFTER
OPERATION. LET THE EXHA UST COOL BEFORE YOU
DO WORK. IF YOU DO NO T, PESONAL INJURY CAN
OCCUR.

Silencer Assembly (09.01)
Exhaust (09.00)
Issue 5, January 2010 Workshop Manual 9-1-5
9. Release the two wiring harn esses for the HEGO sensor
from the clip on the heat shield.
10. Release the HEGO sensor from the catalytic converter.
11. Install an applicable length of string to the wiring harness and the electrical connector for the HEGO sensor.
12. Use the string to put the wiring harness for the HEGO
sensor behind the heat shield.
13. Release the string from the electrical connector for the HEGO sensor.
14. Remove the HEGO sensor.
15. Clean the component mating faces.
Install
1. Put the HEGO sensor into position.
2. Attach an applicable length of string to the wiring harness for the HEGO sensor.
3. Use the string to put the wiring harness for the HEGO
sensor behind the heat shield.
4. Remove and discard the string.
5. Install the HEGO sensor into the catalytic converter.
6. Tighten the HEGO sensor.
7. Put the heat shield into position.
8. Install and tighten the two bolts that attach the heat shield to the torque tube.
9. Install the two wiring harnesses for the HEGO sensor into the clip on the heat shield.
10. Put the bracket into position.
11. Install and tighten the two bolts that attach the bracket to the engine.
12. Connect the two electrical connnectors to the HEGO
sensor.
13. Install the two electrical connnectors for the HEGO sensor into the bracket.
Silencer and Bypass Valve Assembly-
Remove for Access/Refit-Coupe Only
Removal
1. Raise vehicle on ramp.
2. Remove rear undertray (refer to Workshop Manual procedure 01.02.PB Undertray - Rear - Renew). 3. Remove Allen bolts (x4), bumper diffuser to mounting
brackets. Remove diffuser, collect securing brackets.
4. Disconnect both by-p ass valve vacuum lines.
5. Remove bolts (x4), rear exhaust pipes to silencer. Collect springs from bolts.
6. Remove bolts (x4), securing LH and RH silencer rear hanger brackets to body.
7. Remove bolts (x4), silencer front mountings to subframe.
8. Position suitable lifter to support weight of silencer. With assistance, remove silencer.
9. Remove both rear rubber mountings and hanger brackets from silencer.
Installation
1. Clean muffler and mating faces on rear pipes.
2. Position silencer on lifter. Install silencer, position rear
hangers, install and torque tighten bolts (x4).
3. Position front mountings to subframe, install and torque
tighten bolts (x4).
4. Align silencer to rear pipes, install springs (x4), install and torque tighten bolts (x4).
5. Check silencer to rear pipes for correct alignment and clearances.
6. Connect lines to both by-pass vacuum valves.
7. Position mounting brackets, install rear bumper diffuser. Install and tighten Allen bolts.
8. Install rear undertray (refer to Workshop Manual procedure 01.02.PB Undertray - Rear - Renew).
9. Lower vehicle on ramp.
Silencer and Bypass Valve Assembly-
Remove for Access/Refit-Roadster Only
Removal
1. Raise vehicle on ramp.
CAUTION
Turn the electrical harness for the HEGO sensor when
you remove the sensor in the step that follows. If you do not, the harness can be damaged.
CAUTION
Turn the electrical harness for the HEGO sensor when
you remove the sensor in the step that follows. If you do not, the harness can be damaged.
Repair Operation Time (ROT)
WA R N I N G
THE EXHAUST SYSTEM WILL BE VERY HOT AFTER
OPERATION. LET THE EXHAUST COOL BEFORE YOU DO WORK. IF YOU DO NO T, PESONAL INJURY CAN
OCCUR.
WA R N I N G
GET THE AID OF ONE MORE PERSON WHEN YOU
REMOVE THE REAR EXHAUST SILENCER.
THE SILENCER IS HEAVY .
WA R N I N G
GET THE AID OF ONE MORE PERSON WHEN YOU INSTALL THE REAR EXHAUST SILENCER.
THE SILENCER IS HEAVY .
Ensure correct alignment of exhaust pipes and silencer before tightening of fixing clamps.
Repair Operation Time (ROT)

Silencer Assembly (09.01)
Exhaust (09.00)9-1-8 Workshop Manual Issue 5, January 2010
9. Remove nut (x8) securing RH exhaust manifold to cylinder head (refer to Fig. 1).
10. Remove nut (x2) on RH engine mounting.
11. Raise engine by approximately 25mm.
12. Remove RH exhaust manifold from vehicle and discard
gasket.
13. Remove heatshield from manifold (bolts x4)
14. Remove nuts (x8) securing LH exhaust manifold to
cylinder head.
15. Remove exhaust manifold, remove and discard gasket.
Installation
1. Clean LH exhaust manifold and mating face on cylinder head. Install new manifold gasket.
2. Install LH exhaust manifold to cylinder head.
3. Install and torque tighten nuts (x8) securing exhaust manifold to cylinder head.
4. Clean exhaust manifold and mating face on engine. Install new gasket to engine.
5. Install heatshield to manifold (bolts x4)
6. Install RH exhaust mani fold to cylinder head.
7. Install nut (x8) securing manifold to cylinder head
(torque).
8. Lower engine.
9. Install nuts (x2) on engine mounts (torque).
10. Install (nuts x2) EGR pipe from manifold, clean mating face and fit new gasket (torque).
11. Install heatshield deflector, front floor (refer to Workshop Manual procedure 09.04.AA Heatshield -
Front Floor - Renew).
12. Tighten EGR pipe in valve (torque).
13. Install RH front wheel arch liner (refer to Workshop Manual procedure 01.02.GB Wheel Arch Liner - Front -
RH - Renew
14. Install LH wheel arch liner (refer to Workshop Manual procedure 01.02.FB Wheel Arch Liner - Front - LH -
Renew).
15. Lower vehicle on ramp. 16. Connect vehicle battery.
Exhaust System (Excluding Manifold/
Downpipes)-Renew
Removal
1. Raise vehicle on ramp.
2. Remove undertrays - vehicle set (refer to Workshop
Manual procedure 01.02.PD Undertrays - Vehicle Set -
Renew).
3. Remove Allen bolts(x4), bumper diffuser to mounting brackets. Remove diffuser
4. Disconnect both by-pass valve vacuum lines.
5. Remove bolts (x4), securing LH and RH silencer rear
hanger brackets to body. Remove hanger brackets.
6. Remove bolts (x4), rear exha ust pipes to silencer. Collect
springs from bolts
7. Remove bolts (x4), silencer front mountings to subframe. Remove mountings from silencer.
8. Position suitable lifter to support weight of silencer. with assistance, remove silencer.
9. Mark rear stub pipes to si lencer for assembly purposes.
10. Loosen clamps (x2), rear stub pipes to silencer. Remove stub pipes and clamps.
11. Remove bolts (x4), remove rear subframe cross brace.
12. Loosen clamps (x2), release RH and LH rear pipes from centre pipe.
13. Remove rear pipes through subframe.
14. Loosen clamps (x2), centre pipe to LH and RH catalysts.
15. Coupe Only - Release centre pipe from mountings, LH
and RH catalysts, remove centre pipe.
16. Roadster Only - Remove centre exhaust mounting bolts
(x4).
17. Release LH and RH catal ysts, remove centre pipe.
18. Disconnect multiplugs (x4), from each catalyst.
19. Coupe Only - Secure sufficient lengths of string to
HEGO sensor multiplugs for assembly purposes.
Figure 1
A090069
Repair Operation Time (ROT)
ItemCode
Exhaust System (Excluding Manifold/
Downpipes)-Renew 09.00.NB
WAR NI NG
TO AVOID PERSONAL INJURY, I.E. SEVERE BURNS TO
THE SKIN, ALLOW EXHAUS T SYSTEM TO COOL
DOWN BEFORE REMOVING EXHAUST SYSTEM COMPONENTS.
WAR NI NG
GET THE AID OF ONE MORE PERSON WHEN YOU
REMOVE THE REAR EXHAUST SILENCER.
THE SILENCER IS HEAVY .
Attach lengths of string to th e HEGO sensor multiplugs. This
enables routing the HEGO sensor harness behind the exhaust heat shield on assembly.

Silencer Assembly (09.01)
Exhaust (09.00)
Issue 5, January 2010 Workshop Manual 9-1-9
20. Coupe Only - Remove cable ties (x2) from LH and RH
HEGO sensor harnesses.
21. Remove nuts (x6), securing each catalyst to exhaust manifolds.
22. With assistance, remove catalysts (x2), release HEGO sensor harnesses from behind heat shield.
23. Coupe Only - Remove string from multiplugs.
24. Discard gaskets (x2) from exhaust manifolds.
25. Coupe Only - Remove bolts (x11), heatshields to centre,
LH and RH rear pipes. Remove heatshields.
Installation
1. Clean heatshields.
2. Coupe Only - Position heatshields to centre, LH and RH
rear pipes. Install and tighten bolts.
3. Install new flange gaskets to exhaust manifolds.
4. With assistance, install both catalysts, install and torque tighten nuts (x6).
5. Roadster Only - Install bolts (x4) and nuts (x2) to
catalyst heatshield.
6. Coupe Only - Feed HEGO sensor harnesses behind
heat shield, secure harnesses with cable ties.
7. Apply exhaust sealant to cent re pipe, install centre pipe
to catalysts and centre mounting. Do not torque clamp
nuts at this stage.
8. Roadster Only - Install centre exhaust mounting bolts
(x4).
9. Apply exhaust sealant to LH and RH rear pipes.
10. Install LH and RH rear pi pes to centre pipe. Do not
torque clamp nuts at this stage.
11. Install both rear rubber mountings and hanger brackets to silencer.
12. Position silencer on lifter . Install silencer, position
hangers, install and tighten bolts (x4).
13. Install front mountings to silencer, install and tighten bolts (x4).
14. Align silencer to rear pipes, install springs (x4) and bolts (x4). Do not torque bolts at this stage.
15. Install and align stub pipes (x2) to silencer and to trims in
bumper.
16. Align clamps, do not torque tighten.
17. Connect lines to both by-pass vacuum valves.
18. Coupe Only - Remove string from multiplugs.
19. Connect multiplugs to HEGO sensors. 20. Working from front to rear, set all exhaust to body
clearances.
21. Tighten all exhaust fixings to the correct torque.
22. Install subframe cross brace, install and torque tighten bolts (x4).
23. Position mounting brackets, install rear bumper diffuser. Install and tighten Allen bolts.
24. Install undertrays - vehicle set (refer to Workshop Manual procedure 01.02.PD Undertrays - Vehicle Set -
Renew).
25. Lower vehicle on ramp.
Attach lengths of string to th e HEGO sensor multiplugs. This
enables routing the HEGO se nsor harness behind the
exhaust heat shield on assembly.
WA R N I N G
GET THE AID OF ONE MORE PERSON WHEN YOU
INSTALL THE REAR EXHAUST SILENCER.
THE SILENCER IS HEAVY .
Ensure correct alignment of exhaust pipes and silencer before tightening of fixing clamps.

Pipes and Supports (09.03)
Exhaust System (09.00)
May 2007 Workshop Manual 9-2-1
Exhaust System (09.00)
Pipes and Supports (09.03)
Specifications
Maintenance
RH/LH Catalyst and Pipe Assembly-
Renew
Removal
1. Raise vehicle on ramp.
2. Remove rear exhaust silencer (refer to Workshop Manual procedure 09.00.KA Silencer and Bypass Valve
Assembly - Remove for Access and Refit).
3. Disconnect multiplugs (x2), HEGO sensors.
4. Release sensor lead from clip on heatshield.
5. Secure sufficient lengths of string to HEGO sensor multiplugs for assembly purposes.
6. Loosen LH and RH clamp nuts , catalysts to centre pipe.
7. Remove nuts (x3), catalyst to exhaust manifold.
8. With assistance, manoeuvre exhaust centre pipe assembly rearwards to release from catalysts.
9. With assistance, release and support weight of LH/RH catalyst from exhaust manifold.
10. Manoeuvre HEGO sensor le ads and remove cable tie.
Release HEGO sensor leads from behind heat shield.
Remove string from HEGO multiplugs.
11. Remove catalyst assembly.
12. Remove and discard gasket.
13. Remove HEGO sensors (x2) from catalyst.
Installation
1. Clean catalyst, mating joint faces and HEGO sensors.
2. Install and tighten HEGO sensors (x2) to catalyst. 3. Install new gasket to exhaust manifold flange.
4. With assistance, position cata
lyst, secure string (x2) to
HEGO multiplugs, feed sensor leads behind heat shield.
Install catalyst to exhaust manifold.
5. Install and torque tighten nuts (x3), catalyst to exhaust manifold.
6. Align centre pipe assembly to catalyst, torque tighten clamp nuts.
7. Remove string (x2), conne ct multiplugs (x2), HEGO
sensors.
8. Secure sensor lead in clip on heatshield.
9. Install rear exhaust silencer (refer to Workshop Manual procedure 09.00.KA Silencer and Bypass Valve
Assembly - Remo ve for Access and Refit).
10. Lower vehicle on ramp.
Exhaust Centre Pipe-Renew
Removal
1. Raise vehicle on ramp.
2. Remove pipe assembly exha ust rear - RH (refer to
Workshop Manual procedure 09.00. Pipe Assembly -
Exhaust - Rear - RH - Renew).
3. Remove pipe assembly exha ust rear - LH (refer to
Workshop Manual procedure 09.00.JB Pipe Assembly -
Exhaust - Rear - LH - Renew).
4. Loosen clamp nuts (x2), centre pipe to LH and RH catalysts.
5. Release centre pipe from mountings, LH and RH
catalysts, remove centre pipe.
6. Remove bolts (x3), heatshie ld to centre pipe, remove
heatshield.
7. Remove Torx screws (x4), mounting bracket to centre pipe, remove bracket.
Installation
1. Use a proprietary exhaust seal ant around all pipe joints
prior to installation of exhaust system.
2. Install mounting bracket to centre pipe, install and tighten Torx screws (x4).
3. Install heatshield to centre pipe, install and tighten bolts (x3).
4. Apply exhaust sealant to centre pipe joints.
Torque Figures
DescriptionNmlb. / ft.
Catalyst (nuts / bolts) 25.5-34.5 19-25.5
Catalyst (clamps) 19-22 14.5-16.5
Centre pipe to rear pipe (clamp) 39-51 29-38
Rear Pipe to Silencer (bolt) 28-33 21-24.5
Repair Operation Time (ROT)
Attach lengths of string to th e HEGO sensor multiplugs. This
enables routing the HEGO se nsor harness behind the
exhaust heat shield on assembly.
Repair Operation Time (ROT)

Pipes and Supports (09.03)
Exhaust System (09.00)9-2-4 Workshop Manual May 2007
5. Install heatshield deflector, front floor (refer to Workshop Manual procedure 09.04.AA Heatshield -
Front Floor - Renew).
Exhaust Gas Temperature Sensor-Renew
Removal
1. Raise vehicle on ramp.
2. Remove rear exhaust silencer (refer to Workshop Manual procedure 09.00.KA Silencer and Bypass Valve
Assembly - Remove for Access and Refit).
3. Disconnect sensor multiplugs (x2.
4. Release sensor leads from clips (x2) on heatshield.
5. Secure sufficient lengths of string to sensor multiplugs for assembly purposes.
6. Loosen rear LH and RH clamp nuts, catalysts to centre pipe.
7. Remove nuts (x3), catalyst to exhaust manifold.
8. With assistance, manoeuvre exhaust centre pipe assembly rearwards to release from catalysts.
9. With assistance, release and support weight of LH catalyst from exhaust manifold.
10. Manoeuvre sensor leads and remove cable tie. Release sensor leads from behind heat shield. Secure cable tie.
Remove string fr om multiplugs.
11. Remove catalyst assembly.
12. Remove and discard gasket.
13. Remove sensor from catalyst.
Installation
1. Clean catalyst mating joint faces.
2. Install and tighten sensor (x2) (torque).
3. Apply proprietary exhaust sealant around pipe joints.
4. Install new gasket to exhaust manifold flange.
5. With assistance, position catal yst, secure string (x2) to
multiplugs, feed sensor leads behind heat shield. Install
catalyst to exhaust manifold.
6. Install and torque tighten nuts (x3), catalyst to exhaust manifold. 7. Align centre pipe assembly to catalyst, torque tighten
clamp nuts.
8. Remove string (x2), connect multiplugs (x2), sensors.
9. Secure sensor leads in clips on heatshield.
10. Install rear exhaust silencer (refer to Workshop Manual procedure 09.00.KA Silencer and Bypass Valve
Assembly - Remove for Access and Refit).
11. Lower vehicle on ramp.
RH/LH Rear Exhaust Pipe Assembly-
Renew
Removal
1. Raise vehicle on ramp.
2. Remove rear undertray.
3. Remove rear silencer assembly (refer to Workshop Manual procedure 09.00.KA Silencer and Bypass Valve
Assembly - Remove for Access and Refit).
4. Remove bolts (x4), cross brace.
5. Loosen clamp nut, release/remove rear intermediate pipe from centre pipe.
6. Remove rear intermediate pipe through subframe.
7. Remove bolts (x4), heat shields (x2).
8. Remove clamp nut, bolt and washers (x2) from rear intermediate pipe.
Installation
1. Clean rear intermediate pipe and mating faces on centre pipe.
2. Install clamp bolt, washers and nut.
3. Position heat shields (x2), install and torque bolts (x4).
4. Apply a proprietary exhaus t sealant to clamp joint.
5. Install rear intermediate pipe to centre pipe.
6. Align rear intermediate pipe to silencer.
7. Install rear silencer assembly (refer to Workshop Manual procedure 09.00.KA Silencer and Bypass Valve
Assembly - Remove for Access and Refit).
8. Torque tighten clamp nut.
9. Install cross brace, install and torque tighten bolts (x4).
10. Install rear undertray.
11. Lower vehicle on ramp.
Repair Operation Time (ROT)
Repair Operation Time (ROT)
ItemCode
Rear Exhaust Pipe Assembly-Renew RH09.00.HB
Rear Exhaust Pipe Assembly-Renew LH09.00.JB
WAR NI NG
TO AVOID PERSONAL INJURY, I.E. SEVERE BURNS TO
THE SKIN, ALLOW EXHAUS T SYSTEM TO COOL
DOWN BEFORE REMOVING EXHAUST SYSTEM COMPONENTS.

May 2007 Workshop Manual 10-1-1
Fuel (10.00)
Contents
Fuel Tank and Lines (10.01) ................................ 10-1-2Description ............................................................. 1-2 Fuel Tank............................................................... 1-3
Fuel Pumps ............................................................ 1-3
Jet Pumps .............................................................. 1-4
Filler Neck and Check Valve .................................. 1-4
Valves and Sensors ................................................. 1-5
Fuel System Schematic ........................................... 1-5
Evaporative Loss System ......................................... 1-6 System Operation .................................................. 1-6
Fuel Tank Vents and Control Valves ....................... 1-6
Safety Precautions .................................................. 1-7
Specifications.......................................................... 1-7
Maintenance ........................................................... 1-8 Fuel System ........................................................... 1-8
Fuel Filter Assembly-Renew .. ................................. 1-8
Fuel Pump and Reservoir Assembly-Renew ............ 1-9
Fuel Tank and Canister Assembly-Renew ............. 1-11
Fuel Tank and Canister Assembly-Remove
for Access/Refit ................................................... 1-13
Fuel Tank Sender Assembly-Renew ...................... 1-15
Fuel Vapour Pipe Assembly-Renew ...................... 1-16
Fuel Supply and Vapour Pipe Assembly-Renew .... 1-17
Manifold Supply Fuel Pipe Assembly- Renew ....... 1-17

Fuel Tank and Lines (10.01)
Fuel (10.00)10-1-2 Workshop Manual May 2007
Fuel (10.00)
Fuel Tank and Lines (10.01)
Description
This vehicle uses a return less fuel system in which the fuel pump, controlled by the fuel pump driver module, is run to
supply fuel through one in-tank filter to the fuel rail (Refer to ’Fuel Charging System (03.04)’, page 3-5-1). A pressure senso r
and a temperature sensor are fitted on th e primary fuel rail. The fuel pump speeds are varied as required to regulate the
fuel pressure in the fuel rails.
$GGQRLQLOOXVWUDWRU
6DYHDVSGI
5HRSHQLQSKRWRVKRSDQGVDYHDVGSLSGI
3XPS
)XHO)LOWHU
)XHO5DLOV )XHO3XPS
'ULYHU0RGXOH
)LOO/LPLW9HQW9DOYH
(OHFWULFDO
&RQQHFWRU