ASTON MARTIN V8 VANTAGE 2010 Workshop Manual

Engine Structure (03.01)
Issue 4, November 2008Workshop Manual 3-1-3
Knock Sensors
Two knock sensors (1) are installed into the cylinder block on the inboard side of each of the two cylinder banks. The
electrical connector of each sensor is secured to th e left-hand engine cover bracket (Refer to Figure 4).
These piezo-electric sensors send inputs to the ECM to indicate the detection and location of detonation during
combustion.
Bedplate
This is a structural casting that is attached with bolts to the bottom
of the cylinder block t attach the crankshaft and to further
improve overall rigidity.
Main bearing clearance changes due to expansion are minimized
by means of iron inserts cast into the bedplate main bearing
supports.
Two hollow dowels align the bedplate with the cylinder block and
the joint is sealed by a continuous bead of sealant.

Engine Mountings
The engine is mounted at two points. At the front, on ea ch side of the engine, there is a mounting bracket with a
Hydramount mounted to the subframe.
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Engine Structure (03.01)
3-1-4Workshop ManualIssue 4, November 2008
Cylinder Heads
The cylinder heads are unique to each cylinder bank and are attached with deep seated bolts, to the cylinder block. Two
hollow dowels align each cylinder head with the cylinder block.
Each cylinder head gasket has a silicon beaded compos ite gasket with metal eyelets for the cylinder bores.
There are two overhead camshafts that operate four valves each cylinder with solid aluminium-alloy valve lifters. A steel
shim in the top of each lifter gives adjustment of the valve clearances.
Collets, valve collars and spring seats locate the valve springs on the intake and exhaust valves. Valve stem seals are part
of the spring seats.
Four 14mm diameter spark plugs are installed in recesses on the center-line of each cylinder head.
Inlet/Exhaust Manifolds
Intake air is filtered and passed through Mass Air Flow (MAF) meters. The air then passes through the throttle body into
the eight-branch inlet manifold.
Specifications
8
9
7
2
3
4
5
6
1
E 43444
ItemDescriptionItemDescription
1.
2.
3.
4. Camshaft bearing cap
Tappet (No Shim)
Collet
Valve spring cap
Va l v e s p r i n g 5.
6.
7.
8.
Valve stem oil seal
Va l v e
Inlet camshaft
Exhaust camshaft
Torque Figures
DescriptionNm.lb/ft
Cylinder head All All1.
2.20
35 15
26
Bolts 1 to 10
Bolts 1 to 10 3.
4.90°
90°
Bolts 11 and 12 5. 25 18

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)
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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.
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Engine Structure (03.01)
3-1-8Workshop ManualIssue 4, November 2008
23. Install fuel feed pipe.
24. Install purge pipe P-clip.
25. Install harness bracket to engine.
26. Refit harness fir tree clips to cylinder head.
27. Refit engine breather hose.
28. Install VVT solenoid multiplug, position coil and CMP
harness (1x edge clip).
29. Install corner cross brace (torque bolts with vehicle on level ground).
30. Install coil cover.
Installation LH Side
31. Connect breather hose to manifold (quickfit).
32. Connect IAT multiplug.
33. Install injector harness to cam cover (x2).
34. Connect injector multiplugs (x4).
35. Install pipe support bracket (nuts x2, bolts x2).
36. Install harness support bracket (bolt x1, nut x2) release harness clips (fir tree x3).
37. Connect booster hose to manifold and support clip.
38. Connect heater hose from pipe (quick fit).
39. Install heater hose (x2) and throttle body hose (x2) from
support bracket.
40. Connect purge line to manifold and into support clip.
41. Connect breather hoses (x2) to cam cover.
42. Feed harness into inner wing area.
43. Install fusebox to bracket.
44. Install earth lead to fusebox.
45. Install battery lead to fusebox (1x nut and rubber cover).
46. Install multiplugs to fuse box.
47. Install fusebox bracket fixings.
48. Install ECM (see Workshop Manual procedure 03.13.ND Module - Power Train Control - RHD -
Renew).
49. Install coil cover.
50. Refill coolant (see Workshop Manual procedure 03.03.AD Coolant - Drain and Refill).
51. Install cross brace. (torque bolts with vehicle on level
ground).
Upper Intake Manifold Assembly Gasket
(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 R/H Side
4. Remove coil cover.
5. Disconnect breather hose (quick fit) move aside.
6. Release (alt/inj) harness fir tr
ee 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 03.13.NC Module - Powe r Train Control - Renew).
9. Remove battery lead (x1nut and rubber cover) from fuse box (2x leads).
10. Remove multiplugs (x10) from fusebox.
11. Remove earth terminal (1x 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 to gain access to cam cover.
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 (inj/alt) harness from coolant pipe bracket (fir tree x3).
21. Disconnect EGR (x1), fuel rail pressure sensor (x1) and injector multiplugs (x4), move harness aside.
22. Remove coolant pipe bracke t (nuts x2 and bolts x2).
23. Disconnect EGR vacuum pipe from sensor and
manifold, move aside.
Removal L/H 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).
Repair Operation Time (ROT)

Engine Structure (03.01)
Issue 4, November 2008Workshop Manual 3-1-9
Removal Manifold
37. Disconnect manifold heating hoses (x2).
38. Disconnect throttle body multiplug and harness clip.
39. Disconnect breather pipe qu ickfits (x2) from air cleaner
duct.
40. Disconnect air clea ner 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.
Installation
Manifold to Vehicle
1. Install new gaskets to cylinder block (glue in place).
2. Install manifold (allowing access to install bolt for purge line P-clip).
3. Install manifold bolts (x10) (torque and tightening sequence).
4. Install bolts (x2) bracket to manifold (rear).
5. Connect EGR pipe union.
6. Connect EGR vacuum hose.
7. Connect air cleaner duct (clip x1).
8. Connect breather pipe quickf its (x2) to air cleaner duct.
9. Connect throttle body multiplug and harness clip.
10. Connect manifold heating hoses (x2).
Installation RH Side
11. Connect EGR vacuum pipe to sensor and manifold.
12. Install coolant pipe bracket (bolt x2, nut x2).
13. Connect EGR (x1), fuel rail pressure sensor (x1) and
injector multiplugs (x4).
14. Refit (inj/alt) harness to coolant pipe bracket (fir tree x3).
15. Connect heater hose to pipe (quick fit).
16. Refit heater hose (clipx2) and EGR vacuum lines (clips x2) to bracket.
17. Install fuel feed pipe.
18. Install purge pipe P-clip.
19. Install harness bracket to engine. 20. Feed harness into inner wing area.
21. Install fusebox to bracket.
22. Install earth lead to fusebox.
23. Install battery lead to fusebox (1x nut and rubber cover).
24. Install multiplugs to fuse box.
25. Install fusebox bracket fixings.
26. Refit harness fir tree clips to cylinder head.
27. Refit engine breather hose.
28. Install VVT solenoid multip
lug, position coil and CMP
harness (1x edge clip).
29. Install ECM (see Workshop Manual procedure 03.13.NC Module - Power Train Control - Renew).
30. Install coil cover.
Installation LH Side
31. Connect breather hose to manifold (quickfit).
32. Connect IAT multiplug.
33. Unclip injector harness from cam cover (x2).
34. Connect injector multiplugs (x4).
35. Install pipe support bracket (nuts x2, bolts x2).
36. Install harness support bracket (bolt x1, nut x2) release harness clips (fir tree x3).
37. Connect booster hose to manifold and support clip.
38. Connect heater hose from pipe (quick fit).
39. Install heater hose (x2) and throttle body hose (x2) from support bracket.
40. Connect purge line to manifold and into support clip.
41. Connect breather hoses (x2) to cam cover.
42. Install coil cover.
43. Install corner cross brace (t orque bolts with vehicle on
level ground).
44. Refill coolant (see Workshop Manual procedure 03.03.AD Coolant - Drain and Refill).
45. Install cross brace. (torque bolts with vehicle on level
ground).
Upper Intake Manifold Assembly Gasket
(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.
A030113
Note: The installation is not handed
Repair Operation Time (ROT)

Engine Structure (03.01)
3-1-10Workshop ManualIssue 4, November 2008
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 bracket (nuts x2 and bolts x2).
15. Disconnect EGR vacuum pipe from sensor and manifold, move aside.
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 - Power Train Control - RHD -
Renew).
21. Remove battery lead (1x nu t 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 brack et (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 cleaner 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.
Installation
1. Install new gaskets to cylinder block (glue in place).
2. Install manifold (allowing access to install bolt for purge line P-clip).
3. Install manifold bolts (x 10) (torque and tightening
sequence).
4. Install bolts (x2) bracket to manifold (rear).
5. Connect EGR pipe union.
6. Connect EGR vacuum hose.
7. Connect air cleaner duct (clip x1).
8. Connect breather pipe quickfits (x2) to air cleaner duct.
9. Connect throttle body multiplug and harness clip.
10. Connect manifold heating hoses (x2).
11. Install booster hose to support bracket.
Installation RH Side
12. Connect EGR vacuum pipe to sensor and manifold.
13. Install coolant pipe bracket (bolt x2, nut x2).
14. Connect EGR (x1), fuel rail pressure sensor (x1) and injector multiplugs (x4).
15. Refit harness to coolant pipe bracket (fir tree x3).
16. Connect heater hose to pipe (quick fit).
17. Refit heater hose (clipx2) and EGR vacuum lines (clips
x2) to bracket.
18. Install fuel feed pipe.
19. Install purge pipe P-clip.
20. Install harness bracket to engine.
21. Refit harness fir tree clips to cylinder head.
22. Refit engine breather hose.
A030113

Engine Structure (03.01)
Issue 4, November 2008Workshop Manual 3-1-11
23. Install VVT solenoid multiplug, position coil and CMP
harness (1x edge clip).
24. Install corner cross brace (t orque bolts with vehicle on
level ground).
25. Install coil cover.
Installation LH Side
26. Connect breather hose to manifold (quickfit).
27. Connect IAT multiplug.
28. Install injector harness to cam cover (x2).
29. Connect injector multiplugs (x4).
30. Install pipe support bracket (nuts x2, bolts x2).
31. Install harness support bracket (bolt x1, nut x2) release harness clips (fir tree x3).
32. Connect booster hose to manifold and support clip.
33. Connect heater hose from pipe (quick fit).
34. Install heater hose (x2) and throttle body hose (x2) from support bracket.
35. Connect purge line to mani fold and into support clip.
36. Connect breather hoses (x2) to cam cover.
37. Feed harness into inner wing area.
38. Install fusebox to bracket.
39. Install earth lead to fusebox.
40. Install battery lead to fusebox (1x nut and rubber cover).
41. Install multiplugs to fuse box.
42. Install fusebox bracket fixings.
43. Install ECM (see Workshop Manual procedure 03.13.ND Module - Powe r Train Control - RHD -
Renew)
44. Install coil cover.
45. Refill coolant (see Workshop Manual procedure 03.03.AD Coolant - Drain and Refill).
46. Install cross brace. (torque bolts with vehicle on level
ground).
Intake Manifold Assembly - Remove for
Access and Refit (With Engine Removed
)
Removal
1. Remove RH coil cover.
2. Disconnect breather hose (quick fit).
3. Release alternator and injector harness fir tree clips (x3) from cylinder head.
4. Remove nut and bolts (x2) securing harness bracket to
engine, remove bracket.
5. Release heater hose (clips x2) and EGR vacuum line (clips x2) from bracket.
6. Release alternator and injector harness fir tree clips (x3) from coolant pipe bracket. 7. Disconnect multiplugs from EGR valve, fuel rail pressure
sensor and injectors (x4).
8. Remove nuts (x2) and bolts (x2) securing coolant pipe
bracket, remove bracket.
9. Disconnect EGR vacuum pipe from sensor and manifold.
10. Remove LH coil cover.
11. Disconnect breather hoses (x2) from LH engine cover.
12. Disconnect purge line from manifold (quickfit) and
support clip for access.
13. Disconnect heater hose from pipe (quick fit).
14. Release heater hose (x2) and throttle body hose (x2) from support bracket.
15. Remove bolt and nuts (x2) securing harness support bracket, release harness clips (fir tree x3). Remove
bracket.
16. Remove nuts (x2) and bolts (x2) pipe support bracket.
17. Disconnect injector multiplugs (x4).
18. Release injector harness clip s (x2) from LH engine cover.
19. Disconnect IAT multiplug.
20. Disconnect breather hose from manifold (quickfit).
21. Disconnect manifold heating hoses (x2).
22. Disconnect throttle body multiplug and harness clip.
23. Disconnect EGR vacuum hose.
24. Loosen and disconnect EGR pipe union from EGR valve.
25. Remove bolts (x2) securing EGR pipe to RH exhaust
manifold, remove pi pe, discard gasket.
26. Progressively loosen and remove bolts (x 10) securing intake manifold to cylinder heads (see Figure 1).
Figure 1
27. Carefully remove intake ma nifold from cylinder heads.
28. Remove and discard gaskets (x2).
Installation
1. Clean intake manifold and mating faces on cylinder heads.
2. Install new gaskets to cyli nder block (glue in place).
3. Install intake manifold (allowing access to install bolt for purge line P-clip).
4. Install and torque tighten in take manifold bolts (x10) in
the correct sequence.
5. Clean EGR pipe and mating face on exhaust manifold.
Repair Operation Time (ROT)
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Engine Structure (03.01)
3-1-12Workshop ManualIssue 4, November 2008
6. Install new gasket on exhaust manifold.
7. Install EGR pipe to exhaust manifold and EGR valve.,
8. Install EGR pipe to EGR valve, install pipe union. Do not
torque tighten at this stage.
9. Install and torque tighten bolts (x2), EGR pipe to exhaust manifold. Torque tighten pipe union.
10. Connect EGR vacuum hose.
11. Connect throttle body multiplug and harness clip.
12. Connect manifold heating hoses (x2).
13. Connect EGR vacuum pipe to sensor and manifold.
14. Install coolant pipe bracket, install and torque tighten bolts (x2) and nuts (x2).
15. Connect multiplugs to EGR valve, fuel rail pressure
sensor and injectors.
16. Install alternator and injector harness fir tree clips (x3) to coolant pipe bracket.
17. Install heater hose clips (x2) and EGR vacuum lines clips (x2) to bracket.
18. Install harness bracket to engine.
19. Refit harness fir tree clips to cylinder head.
20. Refit engine breather hose.
21. Install VVT solenoid multiplug, position coil and CMP harness (1x edge clip).
22. Install coil cover.
23. Connect breather hose to manifold (quickfit).
24. Connect IAT multiplug.
25. Secure injector harness clips (x2) to LH engine cover.
26. Connect injector multiplugs (x4).
27. Install pipe support bracket, install and tighten nuts (x2
and bolts(x2).
28. Install harness support bracket, install and tighten bolt (x1) and, nut (x1).
29. Install heater hoses (x2) an d throttle body hoses (x2) in
support bracket.
30. Connect breather hoses (x2) to engine cover.
31. Install coil cover.
RH/LH Cylinder Head Gasket - Renew
Removal
1. Re-install front subframe to body, install and tighten bolts (x6), remove support trolley.
2. Install and tighten engine mounting nuts (x2).
3. With assistance, remove engine lifting beam (SPX M553D). 4. Remove SAI pump and bracket assembly (see Workshop
Manual procedure 03.08.DB/03.08.DJ Pump and
Bracket Assembly - Secondary Air Injection - Renew).
5. Disconnect multiplugs (x2) from knock sensors.
6. Disconnect multiplug from camshaft timing sensor.
7. Remove RH/LH exhaust manifold (see Workshop Manual procedure 09.00.CC/09.00.CD Gasket -
Exhaust Manifold - RH/LH - Renew).
8. Remove RH/LH intake camshaft (see Workshop Manual procedure 03.09.AT/03.09.AV Camshaft - Intake - RH/
LH - Renew).
9. Remove RH exhaust camshaft bearing cap retaining bolts (x10) evenly and in stages (see Figure 1).
Figure 1
10. Note their orientation and markings and remove the RH
exhaust camshaft bearing caps.
11. Remove RH exhaust camshaft (see Figure 2).
12. Remove bolts (x2) securing front end of RH cylinder
head to cylinder block.
Repair Operation Time (ROT)
Figure 2
A0309258
A0309260