fuel ASTON MARTIN V8 VANTAGE 2010 User Guide

Handles and Lock Mechanisms (01.14)
Body System (01.00)1-10-6 Workshop Manual May 2007
8. Release bayonet fitting on release catch and remove cable (see Figure 2).
Installation
1. Install fuel filler release cable and secure release catch.
2. Attach cable to fuel filler actuator assembly.
3. Install left-hand front luggage compartment carpet over studs.
4. Install upper left-hand luggage compartment carpet.
5. Install lower left-hand luggage compartment carpet.
6. Connect left-hand luggage compartment lamp and install.
7. Install front luggage compartment carpet.
8. Install luggage compartment lid striker assembly (see Workshop Manual procedu re 01.03.GE Striker
Assembly - Trunk Lid - Renew).
Fuel Flap Release Switch - Renew
Removal
1. Remove Trim - upper panel - front pillar - LH (see Workshop Manual procedure 01.05.BE Trim - Upper
Panel - Front Pillar - LH - Renew).
2. Remove LH front sill plate (see Workshop Manual procedure 01.05.AK Plate - Front Sill - LH - Renew). 3. Remove trim studs (x2) securing lower A-post trim panel
to body (see Figure 1).
4. Disconnect multiplug from fuel flap release switch, remove trim panel (see Figure 2).
5. Depress clips, remove fuel fl ap release switch from trim
panel.
Installation
1. Install switch in trim panel.
2. Position trim panel, connect multiplug.
3. Position A-post trim panel, install trim studs (x2).
4. Install LH front sill plat e (see Workshop Manual
procedure 01.05.AK Plate - Front Sill - LH - Renew).
5. Install Trim - upper panel - front pillar - LH (see Workshop Manual procedure 01.05.BE Trim - Upper
Panel - Front Pillar - LH - Renew).
Figure 2
Repair Operation Time (ROT)
Figure 1
Figure 2
A0114168
A0114169

Subframes (02.03)
Frame and Mounting (02.00)
May 2007 Workshop Manual 2-1-7
15. Use tool (206-103) and release each handbrake cable from mounting brackets, re lease inner cable eyelets
from calliper levers.
16. Remove bolts (x2) and nuts (x2), handbrake cables to subframe.
17. Use tool (206-103) and release handbrake cables from subframe brackets.
18. Release handbrake cable from clip, tie handbrake cable aside.
19. Loosen and disconnect each brake pipe from body bracket. Plug brake pipes
.
20. Remove bolt, fuel filler pipe to damper mounting.
21. Remove nut securing fuel fi ller pipe to body, tie filler
pipe aside.
22. Remove bolts (x4 each side), securing spring/damper assemblies.
23. Position drain tray to collect oil spillage.
24. Loosen and disconnect unions (x2), transaxle oil cooler.
Plug pipe connections.
25. Remove drain tray.
26. Disconnect multiplug, release harness clips (x2), transaxle harness, RH rear wheel arch.
27. Mark subframe position to body.
28. Position subframe trolley (303-F715), under subframe.
29. Lower vehicle until subfra me rests on support trolley.
30. Remove bolts (x6), securing subframe to body.
31. Raise vehicle to gain access to gear selector cables.
32. Using (308-642), release se lector cables (x2) from ball
joints, release selector cables from bracket.
33. Remove torque tube to transaxle bolts (x8).
34. Move subframe support trolley rearwards to give a clearance between torque tube and transaxle.
35. Carefully raise vehicle from subframe.
Installation
1. Clean transaxle and mating face on torque tube.
2. Position subframe assembly underneath vehicle.
3. Lower vehicle to align transaxle to propshaft splines.
4. Move subframe assembly forward, engage propshaft splines, locating dowels, transaxle to torque tube.
5. Install bolts (x8), torque tube to transaxle, torque tighten bolts.
6. Install gear selector cables on levers and in bracket.
7. Lower vehicle onto subframe mountings, align to marks, install and torque tighten bolts (x6).
8. Position spring/damper assemblies, install bolts (x8).
9. Position fuel filler pipe, install and torque tighten bolt.
10. Position fuel filler pipe to body, install and tighten nut to correct torque.
11. Position handbrake cables to subframe, install bolts (x4), torque bolts. 12. Install handbrake cables to callipers.
13. Remove plugs, install brake pipes.
14. Remove plugs, install transaxle oil cooler pipes, tighten
unions to correct torque.
15. Position earth lead to transaxle, install and torque tighten bolt.
16. Install transaxle harness multiplug, secure harness clips (x2).
17. Install shear plate, install and torque tighten bolts (x8).
18. Install heat shield, install and torque tighten bolts (x4).
19. Clean exhaust pipe connections, apply exhaust sealant to connections.
20. Install centre pipe to mountings and catalysts, torque tighten clamp nuts.
21. Install rear exhaust pipes to centre pipe, torque tighten clamp nuts.
22. Position subframe cross brace, install and torque bolts.
23. Install rear muffler (see Workshop Manual procedure 09.00.KA Silencer and Bypass Valve Assembly - Remove
for Access and Refit).
24. Install LH rear wheel arch liner (see Workshop Manual procedure 01.02.JB Wheel Arch Liner - Rear - LH -
Renew).
25. Install RH rear wheel arch liner (see Workshop Manual procedure 01.02.HB Wheel Arch Liner - Rear - RH -
Renew).
26. Bleed brake system (see Workshop Manual procedure 06.07.DD Brake Hydraulic System - Flush/Refill/Bleed
27. Adjust handbrake (see Wo rkshop Manual procedure
06.05.DC Handbrake Cable Assembly - Adjust).
28. Install road Wheel(s).
29. Lower vehicle on ramp and remove safety equipment.
Rear Subframe-Remove/Refit
Removal
1. Disconnect vehicle battery.
2. Remove rear subframe asse mbly (see Workshop Manual
procedure 02.01.CA Subframe Assembly - Rear -
Remove for Access and Refit).
3. Mark driveshafts to transaxle flanges for assembly purposes.
4. Remove and discard Allen bolts (x12), collect plates (x6), driveshaft flanges to transaxle.
5. Attach slings to transaxle, connect suitable hoist and
take weight of transaxle.
6. Remove nuts (x2). hydramounts to subframe.
7. With assistance, raise and remove transaxle from subframe.
Caution
Always plug pipe connections to prevent ingress of dirt.
Repair Operation Time (ROT)

Issue 5, January 2010 Workshop Manual 3-0-1
Engine System (03.00)
Contents
Engine Assembly (03.00) ....................................... 3-0-3Description ............................................................. 0-3
Maintenance ........................................................... 0-4Engine Assembly-Renew ........................................ 0-4
Engine Assembly-Remove for Access and Refit ....... 0-4
Engine Structure (03.01) ........................................ 3-1-1 Description ............................................................. 1-1Engine Block .......................................................... 1-1
Cylinder Block Drain Plug ...................................... 1-2
Knock Sensors........................................................ 1-3
Bedplate ................................................................ 1-3
Engine Mountings .................................................. 1-3
Cylinder Heads ...................................................... 1-4
Inlet/Exhaust Manifolds .......................................... 1-4
Specifications.......................................................... 1-4
Maintenance ........................................................... 1-5 Upper Intake Manifold Assembly (LHD) - Renew ... 1-5
Upper Intake Manifold Asse mbly (RHD) - Renew ... 1-6
Upper Intake Manifold Assembly Gasket (LHD)
- Renew ................................................................. 1-8
Upper Intake Manifold Assembly Gasket (RHD)
- Renew ................................................................. 1-9
Intake Manifold Assembly - Remove for Access
and Refit (With Engine Removed)......................... 1-11
RH/LH Cylinder Head Gasket - Renew................. 1-12
RH/LH Cylinder Head - Overhaul ........................ 1-13
Cylinder Head (Engine Set) - Overhaul ................. 1-14
Valve Set (Engine Set) - Renew
(including de-coke) .............................................. 1-15
Inlet Valve (Set) - Renew ...................................... 1-16
Exhaust Valve (Set) - Renew ................................. 1-16
Spring (Valve Set) - Renew ................................... 1-17
Spring (Inlet Valve Set) - Renew ........................... 1-18
Inlet and Exhaust Valve Seal (Engine Set) - Renew 1-19
Spring (Valve Exhaust Set) - Renew....................... 1-19
RH/LH Cylinder Head Gasket - Renew (with
Engine Removed) ................................................. 1-20
Cylinder Head Gasket (E ngine Set) - Renew (with
Engine Removed) ................................................. 1-21
Lubrication System (03.02) .. .................................. 3-2-1
Dry Sump System .................................................. 2-1
Specifications.......................................................... 2-2 Engine Oil Specification ......................................... 2-2
Maintenance ........................................................... 2-2 Oil Pressure Pump to Sump Gasket - Renew .......... 2-2
Oil Pump Chain - Renew ....................................... 2-2
Oil Sump Pan - Renew........................................... 2-3
Oil Sump Pan - Remove and Reseal ....................... 2-5
Oil Cooler - Renew ................................................ 2-8
Oil Cooler Tank Assembly - Renew ........................ 2-9
Thermostat - Renew ............................................... 2-9
Oil Cooler Tank Pipe Assembly - Renew .............. 2-10
Oil Thermostat to Tank Tube Assembly - Renew .. 2-10
Oil Pump Inlet Tube Assemb ly - Renew ............... 2-11 Oil Pump Inlet Tube Assembly - Renew ............... 2-12
Oil Pump Outlet Tube Asse
mbly - Renew ............ 2-12
Oil Thermostat Cooler Pipe Assembly - Renew .... 2-13
Oil Temperature Controller - Renew .................... 2-14
Oil Sump Pan - Renew (with Engine Removed) .... 2-14
Oil Sump Pan - Remove and Reseal
(with Engine Removed) ........................................ 2-17
Cooling System (03.03) ......................................... 3-3-1 Description ............................................................. 3-1Water Pump .......................................................... 3-1
Thermostat ............................................................ 3-1
Radiator................................................................. 3-1
Cooling Fans .......................................................... 3-1
Coolant Reservoir .................................................. 3-1
Engine Oil Cooler .................................................. 3-2
Specifications......................................................... 3-2
Torque Figures ....................................................... 3-2
Maintenance ........................................................... 3-2 Coolant-Drain/Fill .................................................. 3-2
Thermostat - Renew............................................... 3-3
Water Pump - Renew ............................................ 3-3
Water Pump Pulley - Renew .................................. 3-3
Oil Temperature Controller - Renew ...................... 3-4
Radiator Fan and Motor Assembly - Remove and
Install ..................................................................... 3-4
Radiator and Condenser Assembly - Renew ........... 3-5
Radiator Assembly - Renew.................................... 3-5
Air Conditioning Condenser - Renew ..................... 3-6
Radiator Fan Modulator - Remove and Install......... 3-6
Expansion Tank Assembly - Renew ........................ 3-6
Coolant Recovery Tank Assembly - Remove and
Install ..................................................................... 3-7
Engine Coolant Reservoir Hose - Renew ................ 3-8
Water Inlet/Outlet Manifold - Renew ..................... 3-8
Engine Electric Coolant Temperature Sensor
- Renew ............................................................... 3-10
Thermostat Cover - Renew .................................. 3-11
Fuel Charging System (03.04)................................ 3-4-1 Safety Precautions .................................................. 4-1
Maintenance ........................................................... 4-2Fuel Rails - Renew ................................................. 4-2
Fuel Injection Pressure Sensor - Renew .................. 4-3
Fuel Temperature Sensor - Renew ......................... 4-3
Fuel Injector Engine Set - Renew............................ 4-4
Fuel Injector - Each - LH Bank - Renew.................. 4-5
Fuel Injector - Each - RH Bank - Renew ................. 4-5
Engine Set - Fuel Injector - LH Bank - Renew ......... 4-6
Engine Set - Fuel Injector - RH Bank - Renew......... 4-6
Accessory Drive System (03.05) ............................ 3-5-1 Description ............................................................. 5-1Auxiliary Drives...................................................... 5-1
Automatic Belt Tensioner ....................................... 5-1
Specifications ......................................................... 5-1
Maintenance ........................................................... 5-1

Engine Assembly (03.00)
Engine (03.00)3-0-4 Workshop Manual Issue 5, January 2010
Engine (03.00)
Engine Assembly (03.00)
Description
The engine is an all aluminium 4.3 litre 90° V8 configuration. The cylinder heads have dual
overhead camshafts and four valves per cylinder. An electronic engine management system
controls the sequential multi-port fuel injection and distributor-less ignition systems.
The engine uses the latest ‘fast-burn’ combustion technology. Heated oxygen sensors monitor the
oxygen content of exhaust gasses . The engine management system uses the oxygen sensor signals
together with other engine information to ‘fine tune ’ fuelling levels and ignition timing. This helps
to achieve the best possible fuel bur n with minimum exhaust emissions.
Inlet camshaft variable timing to impr ove engine performance and emissions.
Inlet manifold is design with tuned length runners to improve volumetric efficiency and
performance.
The engine is fitted with a dry sump to improv e oil pickup during high speed cornering.
The exhaust system has hydroforme d internals with a 4 into 2 into 1 design for improved engine
tuning and lower backpressure. Additional oxygen sensors are placed after the catalysts so that
long term catalyst efficiency can be monitored.
The engine runs on unleaded fuel only.

Engine Assembly (03.00)
Engine (03.00)
Issue 5, January 2010 Workshop Manual 3-0-5
Maintenance
Engine Assembly-Renew
Removal
1. Remove engine (refer to Workshop Manual procedure 03.00.AC Engine Assembly - Remove for Access and
Refit).
2. Remove torque tube (bolts x16 and heatsheild bracket).
3. Install engine lifting brackets.
4. Remove engine from subframe (nuts x2) using suitable lifting equipment.
5. Remove engine lifting brack ets (refer to Figure 1).
Installation
1. Install engine lifting brackets to new engine.
2. Install engine to subframe (nuts x2) using suitable lifting
equipment.
3. Remove engine lifting brack ets (refer to Figure 2).4. Install torque tube (bolts x16 and heatsheild bracket).
5. Install engine (refer to Workshop Manual procedure
03.00.AC Engine Assembly - Remove for Access and
Refit).
Engine Assembly-Remove for Access and
Refit
Removal
1. Remove transmission (refer to Workshop Manual procedure 07.03.AA Transaxle Assembly - Manual -
Remove for Access and Refit).
2. Disconnect battery.
3. Raise vehicle on ramp.
4. Depressurise fuel rail (refer to Workshop Manual procedure 10.01.EK Fuel System - Depressurise).
5. Strap vehicle to ramp (front).
Throttle Duct Removal
6. Disconnect breather pipe qu ickfits (x2) from air cleaner
duct (refer to Figure 1).
Repair Operation Time (ROT)
$3#
$3#
Figure 2
Repair Operation Time (ROT)
$3#

Engine Assembly (03.00)
Engine (03.00)3-0-10 Workshop Manual Issue 5, January 2010
60. Disconnect multiplugs (x4) from inside of vehicle RH side of I.P. (refer to Figure 19).
61. Release grommet from body, feed harness from inside of vehicle.
62. Release harness from clips (x11) and position over engine.
Purge Removal
63. Remove bottom screws (x2) and loosen top screw of washer bottle.
64. Disconnect purge pipe from purge valve (move washer
bottle aside).
65. Release pipe from support clips (x2) and move pipe over engine.
Fuel Pipe Removal
66. Remove fuel hose from rail (clip x1).
Clutch Pipe Removal
67. Remove clutch metal pipe from flexible.
68. Remove flexible hose grommet from support bracket.
Subframe/Engine Removal
69. Remove undertray.
70. Mark subframe position.
71. Remove harness clips (x2).
72. Remove load level sensor from subframe (nut and bolt).
73. Support torque tube with transmission jack.
74. Position trolley, support subframe, remove bolts (x12)
raise vehicle.
75. Ensure A/C HP pipe is clear of engine as body is raised.
Installation
Install Subframe/Engine
1. Ensure A/C HP pipe is co rrect position as body is
lowered. 2. Install subframe to body (refer to Figure 20).
3. Remove transmission jack.
4. Install harness clips (x2).
5. Install load level sensor.
6. Install undertray.
7. Lower ramp.
Cooling Install
8. Connect top hose and clip to body (refer to Figure 21).
Figure 19
$3#
Figure 20
Figure 21
$3#
$3#

Engine Assembly (03.00)
Engine (03.00)
Issue 5, January 2010 Workshop Manual 3-0-15
49. Connect multiplugs (x3) RH side of engine bay (refer to Figure 40).
Purge Install
50. Connect purge pipe to purge valve.
51. Install bottom screws (x2) and tighten top screw of washer bottle.
52. Move pipe into position and install pipe to support clips (x2).
Fuel Install
53. Install fuel hose to rail (clip x1).
Clutch Pipe Install
54. Install clutch metal pipe from flexible.
55. Install flexible hose grommet to support bracket.
56. Bleed clutch.
Suspension Install
57. Install front springs and dampers. (refer to Workshop Manual procedure 04.03.AA Spring and Damper
Assembly - Front Pair - Renew).
58. Install RH wheel arch liner (refer to Workshop Manual procedure 01.02.GB Wheel Arch Liner - Front - RH -
Renew
59. Install LH wheel arch liner (refer to Workshop Manual procedure 01.02.FB Wheel Arch Liner - Front - LH -
Renew).
60. Install bottom arms (nut and bolt x4) with uprights and top arm.
61. Install level sens or link to bottom arm (nut x1).
62. Connect level sensor multiplug.
63. Connect track rod ends (nut x2).
64. Install anti-roll bar to links (nuts x2).
65. Install brake discs.
66. Install brake callipers.
67. Install road wheel/s Throttle Duct Install
68. Connect breather pipe quic
kfits (x2) from air cleaner
duct (refer to Figure 41).
69. Install throttle body duct (refer to Figure 42).
General Install
70. Remove strap - vehicle to ramp (front).
71. Lower vehicle on ramp.
72. Connect vehicle battery.
73. Top-up PAS fluid.
74. 4 wheel alignment check/adjust (refer to Workshop Manual procedure 04.00.AD 4 Wheel Alignment -
Check and Adjust).
75. Install transmission (refer to Workshop Manual procedure 07.03.AA Transaxle Assembly - Manual -
Remove for Access and Refit).
76. Use handbook procedure to check oil level.
Figure 40
$3#
Figure 41
Figure 42
$3#
$3#

Engine Structure (03.01)
Issue 4, November 2008Workshop Manual 3-1-5
Maintenance
Upper Intake Manifold Assembly (LHD) -
Renew
Removal
1. Depressurise fuel rail (see Workshop Manual procedure
10.01.EK Fuel System - Depressurise).
2. Coolant drain (see Workshop Manual procedure 03.03.AD Coolant - Drain and Refill).
3. Remove cross brace (bolts x4).
Removal RH Side
4. Remove coil cover.
5. Disconnect breather hose (quick fit) move aside.
6. Release harness fir tree clips (x3) from cylinder head and move aside.
7. Remove fuse box bracket fixings (bolt and nut) (allows movement).
8. Remove ECM (see Workshop Manual procedure 03.14.BB Engine Contro l Module - RH - Renew).
9. Remove battery lead (1x nut and rubber cover) from fuse box (2x leads).
10. Remove multiplugs (x10) from fusebox.
11. Remove earth terminal (x1 nut and rubber cover) from fusebox.
12. Remove fuse box from bracket (bolt x2).
13. Release harness fir tree clips (x3) from engine bracket.
14. Feed harness from inner wing and over engine.
15. Remove purge pipe P-clip (bolt x1) and move pipe aside.
16. Remove harness bracket from engine (bolts x2, nut x1).
17. Release fuel feed hose from rail (clip x1) and move aside.
18. Disconnect heater hose from pipe (quick fit).
19. Release heater hose (clips x2) and EGR vacuum line (clips x2) from bracket.
20. Release harness from coolant pipe bracket (fir tree x3).
21. Disconnect EGR (x1), fuel ra il pressure sensor (x1) and
injector (x4) multiplu gs, move harness aside. 22. Remove coolant pipe bracket (nuts x2 and bolts x2).
23. Disconnect EGR vacuum pipe from sensor and
manifold, move aside.
Removal LH Side
24. Remove corner cross brace.
25. Remove coil cover.
26. Disconnect breather hoses from cam cover (x2) for access.
27. Disconnect purge line from manifold (quickfit) and
support clip for access.
28. Disconnect heater hose from pipe (quick fit).
29. Release heater hose (x2) and throttle body hose (x2) from support bracket.
30. Remove booster hose from manifold and support clip.
31. Remove harness support bracket (bolt x1, nut x2) release harness clips (fir tree x3).
32. Release pipe support bracket (nuts x2, bolts x2) move aside.
33. Disconnect injector multiplugs (x4).
34. Unclip injector harness from cam cover (x2).
35. Disconnect IAT multiplug.
36. Disconnect breather hose from manifold (quickfit).
Removal Manifold from Vehicle
37. Disconnect manifold heating hoses (x2).
38. Disconnect throttle body multiplug and harness clip.
39. Disconnect breather pipe quickfits (x2) from air cleaner duct.
40. Disconnect air cleaner duct (clip x1).
41. Disconnect EGR vacuum hose.
42. Disconnect EGR pipe union and tie aside.
43. Remove manifold bolts (x 10) (see Figure 1).
Figure 1
44. Remove bolts (x2) bracket to manifold (rear).
45. Move manifold (2x people) forward, remove bolt for purge line P-clip, remove manifold.
46. Remove gaskets and clean mating faces.
EGR pipe and exhaust manifold
flanges.
25 18
Camshaft position (CMP) sensor 7 5
Torque Figures
DescriptionNm.lb/ft
Clearance Figures
Exhaust valve0.23mm - 0.27mm
Inlet Valve clearance 0.18mm - 0.22mm
Repair Operation Time (ROT)
A030113

Engine Structure (03.01)
3-1-6Workshop ManualIssue 4, November 2008
Removal Manifold Parts
47. Remove EGR valve (bolts x2) and gasket.
48. Remove IAT sensor.
49. Remove throttle body (bolts x4) and gasket.
50. Remove fuel rail (bolts x4) with injectors.
Installation
1. Install fuel rail (bolts x4) with injectors. (fit new O-rings
to injectors).
2. Install throttle body (bolts x4) and new gasket.
3. Install IAT sensor.
4. Install EGR valve and new gasket.
Installation Manifold to Vehicle
5. Install new gaskets to cylinder block (glue in place).
6. Install manifold (allowing access to install bolt for purge line P-clip).
7. Install manifold bolts (x 10) (torque and tightening
sequence).
8. Install bolts (x2) bracket to manifold (rear).
9. Connect EGR pipe union.
10. Connect EGR vacuum hose.
11. Connect air cleaner duct (clip x1).
12. Connect breather pipe quickf its (x2) to air cleaner duct.
13. Connect throttle body multiplug and harness clip.
14. Connect manifold heating hoses (x2).
Installation RH Side
15. Connect EGR vacuum pipe to sensor and manifold.
16. Install coolant pipe bracket (bolt x2, nut x2).
17. Connect EGR (x1), fuel rail pressure sensor (x1) and injector multiplugs (x4).
18. Refit harness to coolant pipe bracket (fir tree x3).
19. Connect heater hose to pipe (quick fit).
20. Refit heater hose (clipx2) and EGR vacuum lines (clips
x2) to bracket.
21. Install fuel feed pipe.
22. Install purge pipe P-clip.
23. Install harness bracket to engine.
24. Feed harness into inner wing area.
25. Install fusebox to bracket.
26. Install earth lead to fusebox.
27. Install battery lead to fusebox (1x nut and rubber cover).
28. Install multiplugs to fuse box.
29. Install fusebox bracket fixings.
30. Refit harness fir tree clips to cylinder head.
31. Refit engine breather hose.
32. Install VVT solenoid multiplug, position coil and CMP harness (1x edge clip).
33. Install ECM (see Workshop Manual procedure 03.14.BB Engine Control Module - RH - Renew).
34. Install coil cover.
Installation LH Side
35. Connect breather hose to manifold (quickfit). 36. Connect IAT multiplug.
37. Unclip injector harness from cam cover (x2).
38. Connect injector multiplugs (x4).
39. Install pipe support bracket (nuts x2, bolts x2).
40. Install harness support bracket (bolt x1, nut x2) release
harness clips (fir tree x3).
41. Connect booster hose to manifold and support clip.
42. Connect heater hose from pipe (quick fit).
43. Install heater hose (x2) and throttle body hose (x2) from support bracket.
44. Connect purge line to manifold and into support clip.
45. Connect breather hoses (x2) to cam cover.
46. Install coil cover.
47. Install corner cross brace (torque bolts with vehicle on level ground).
48. Refill coolant (see Workshop Manual procedure 03.03.AD Coolant - Drain and Refill).
49. Install cross brace. (torque bolts with vehicle on level
ground).
Upper Intake Manifold Assembly (RHD)
- Renew
Removal
1. Depressurise fuel rail (see Workshop Manual procedure 10.01.EK Fuel System - Depressurise).
2. Coolant drain (see Workshop Manual procedure 03.03.AD Coolant - Drain and Refill).
3. Remove cross brace (bolts x4).
Removal RH Side
4. Remove coil cover.
5. Remove corner cross brace.
6. Disconnect breather hose (quick fit) move aside.
7. Remove purge pipe P-clip (bolt x1) and move pipe
aside.
8. Remove harness bracket from engine (bolts x2, nut x1).
9. Release fuel feed hose from rail (clip x1) and move aside.
10. Disconnect heater hose from pipe (quick fit).
11. Release heater hose (clips x2) and EGR vacuum line (clips x2) from bracket.
12. Release harness from coolant pipe bracket (fir tree x3).
13. Disconnect EGR (x1), fuel rail pressure sensor (x1) and injector (x4) multiplugs, move harness aside.
14. Remove coolant pipe bracke t (nuts x2 and bolts x2).
15. Disconnect EGR vacuum pipe from sensor and
manifold, move aside. Note: The installation is not handed
Repair Operation Time (ROT)
ItemCode
Upper Intake Manifold Assembly-
Renew RHD
03.01.BE

Engine Structure (03.01)
Issue 4, November 2008Workshop Manual 3-1-7
Removal LH Side
16. Remove coil cover.
17. Disconnect breather hoses from cam cover (x2) for
access.
18. Release harness fir tree clips (x3) from cylinder head and move aside.
19. Remove fuse box bracket fixings (bolt and nut) (allows movement).
20. Remove ECM (see Workshop Manual procedure 03.13.ND Module - Powe r Train Control - RHD -
Renew).
21. Remove battery lead (1x nut and rubber cover) from fuse box (2x leads).
22. Remove multiplugs (x10) from fusebox.
23. Disconnect purge line from manifold (quickfit) and
support clip for access.
24. Remove earth terminal (1x nut and rubber cover) from fusebox.
25. Remove fuse box from bracket (bolt x2).
26. Release harness fir tree clips (x3) from engine bracket.
27. Feed harness from inner wing and over engine.
28. Disconnect heater hose from pipe (quick fit).
29. Release heater hose (x2) and throttle body hose (x2) from support bracket.
30. Remove booster hose from manifold and support clip.
31. Remove harness support bracket (bolt x1, nut x2)
release harness clips (fir tree x3).
32. Release pipe support bracket (nuts x2, bolts x2) move aside.
33. Disconnect injector multiplugs (x4).
34. Unclip injector harness from cam cover (x2).
35. Disconnect IAT multiplug.
36. Disconnect breather hose from manifold (quickfit).
Removal Manifold from Vehicle
37. Remove booster hose from support bracket.
38. Disconnect manifold heating hoses (x2).
39. Disconnect throttle body multiplug and harness clip.
40. Disconnect breather pipe qu ickfits (x2) from air cleaner
duct.
41. Disconnect air clea ner duct (clip x1).
42. Disconnect EGR vacuum hose.
43. Disconnect EGR pipe union and tie aside. 44. Remove manifold bolts (x 10) (see Figure 1)
Figure 1
45. Remove bolts (x2) bracket to manifold (rear).
46. Move manifold (2x people) forward, remove bolt for
purge line P-clip, remove manifold.
47. Remove gaskets and clean mating faces.
48. Removal Manifold Parts
49. Remove EGR valve (bolts x2) and gasket.
50. Remove IAT sensor.
51. Remove throttle body (bolts x4) and gasket.
52. Remove fuel rail (bolts x4) with injectors.
Installation
1. Install fuel rail (bolts x4) wi th injectors. (fit new O-rings
to injectors).
2. Install throttle body (bolts x4) and new gasket.
3. Install IAT sensor.
4. Install EGR valve and new gasket.
5. Installation Manifold to Vehicle
6. Install new gaskets to cyli nder block (glue in place).
7. Install manifold (allowing access to install bolt for purge line P-clip).
8. Install manifold bolts (x10) (torque and tightening sequence).
9. Install bolts (x2) bracket to manifold (rear).
10. Connect EGR pipe union.
11. Connect EGR vacuum hose.
12. Connect air cleaner duct (clip x1).
13. Connect breather pipe quickf its (x2) to air cleaner duct.
14. Connect throttle body multiplug and harness clip.
15. Connect manifold heating hoses (x2).
16. Install booster hose to support bracket.
Installation RH Side
17. Connect EGR vacuum pipe to sensor and manifold.
18. Install coolant pipe bracket (bolt x2, nut x2).
19. Connect EGR (x1), fuel rail pressure sensor (x1) and
injector multiplugs (x4).
20. Refit harness to coolant pipe bracket (fir tree x3).
21. Connect heater hose to pipe (quick fit).
22. Refit heater hose (clipx2) and EGR vacuum lines (clips x2) to bracket.
A030113