dry oil ASTON MARTIN V8 VANTAGE 2010 Owner's Manual

Engine Sealing (03.10)
Engine (03.00)
Issue 5, Janauary 2010 Workshop Manual 3-10-13
38. Remove the four Torx bolts that attach the PAS pump mounting bracket to the cylinder block. Remove the
bracket (refer to Figure 9).
Figure 9
39. Remove the 27 bolts that attach the timing cover to the engine. Collect the bracet for the oil separator drain
tube. Remove the timing cover.
40. Remove the outer and inner rubber seals from the timing cover (refer to Figure0).
Figure0
41. Remove the front crankshaft oil seal from timing cover.
Installation
1. Clean the timing cover and mating face on engine.
2. Install the inner and outer seals into timing cover.
3. Apply 3mm x 12mm beads of sealant to the eight joints
on the engine.
4. Install the timing cover. Put the oil separator drain tube bracket in position. Install the 27 bolts and torque the
bolts in the specified sequence. 5. Using tool (303-750), instal
l front crankshaft oil seal.
Remove special tool and seal protector.
6. Clean crankshaft pulley and mating face on crankshaft.
7. Lubricate and install new O-ring seal in crankshaft pulley.
8. Install crankshaft pulley, locking ring and new pulley bolt.
9. Torque tighten crankshaft pulley bolt. Remove special tool (303-1185) from crankcase.
10. Install inspection cover to lower crankcase, install and tighten bolts (x2).
11. Install PAS pump mounting bracket, install and torque tighten Torx bolts (x4).
12. Install PAS pump, install and torque tighten bolts (x3).
13. Install alternator mounting bracket, install and torque tighten Torx bolts (x3).
14. Install alternator, install bolt and nut/bolt and torque tighten
15. Connect battery cable, install and torque tighten nut, secure cover. Connect multiplug.
16. Lubricate seal, install new oil filter.
17. Install oil separator drai n tube clip in bracket.
18. Install oil separator drain tube to timing cover.
19. Install A/C compressor idler pulley, torque tighten bolt.
20. Install alternator idler pulley, torque tighten bolt.
21. Install auxiliary drive belt te nsioner, torque tighten bolt.
22. Install water pump pulley, install bolts (x3).
23. Using a suitable socket ba r, release auxiliary drive belt
tensioner, install drive belt.
24. Torque tighten water pump pulley bolts (x3).
25. Clean coolant manifold and mating faces on cylinder heads.
26. Install new O-ring seals (x2) to coolant manifold.
27. Position coolant manifold, connect temperature sensor
multiplug, install coolant pipe in manifold.
28. Install and torque tighten Torx bolts (x4) that attach the coolant manifold to cylinder heads.
29. Connect coolant hoses (x3) to coolant manifold and
secure clips.
30. Connect engine breather to oil separator.
31. Clean left and right cam covers.
32. Install the right cam cover (Refer to ’Right Side Cam Cover - Remove and Install’, page 3-10-9).
33. Install left cam cover (Refer to ’Left Side Cam Cover -
Remove and Install’, page 3-10-4).
34. Install the engine assembly (refer to Workshop Manual procedure 03.00.AA Engine Assembly - Renew).
Caution
Make sure the cranks haft front oil seal mating faces are
clean and dry.
Caution
Do not remove the crankshaft front oil seal protector
until the oil seal is correctly installed.
If you do, the oil seal can be damaged.
A0310243
A0310245
Caution
The bolt thread in the cran kshaft must be cleaned out
before a new crankshaft pulley retaining bolt is installed.
Note: Check the crankshaft pulley and locking ring for damage.

Power Conversion (03.11)
Engine (03.00)3-11-4 Workshop Manual May 2007
10. Install crankshaft retaining caps (303-534), install and
lightly tighten bolts (x10) (see Figure 8).
Figure 8
11. Install connecting rod bearing caps (x8), install and torque tighten retaining bolts.
12. Remove bolts securing crankshaft retaining caps (303- 534), remove retaining caps (see Figure 9).
Figure 9
13. Apply a 2mm diameter continuous bead of sealant to cylinder block flange ensuring that there are no gaps in
the sealant.
14. Install engine bedplate to cylinder block, install and torque tighten bolts (x34) in the correct sequence.
15. Remove excess sealant from crankshaft rear oil seal
aperture and front face of cylinder block.
16. Clean windage tray.
17. Install windage tray, install and torque tighten bolts (x8). 18. Ensure that oil seal protector is positioned correctly and
install oil seal onto crankshaft flange.
19. Install tool (303-1189) to crankshaft, position nuts on tool against oil seal.
20. Ensure that oil seal and special are parallel to rear of engine.
21. To install oil seal, tighten nuts alternately on tool (303- 1189) until oil seal correctly seated.
22. Remove special tool from crankshaft.
23. Check that the oil se al is located correctly.
24. Clean flywheel and mating face on crankshaft.
25. Install flywheel, align to dowel on crankshaft flange.
26. Install new bolts (x8), install tool (303-1185) to restrain flywheel. Torque tighten bolts (x8) in the correct
sequence.
27. Clean clutch cover and drive plate.
28. Install clutch assembly on flywheel, align to dowels (x3).
29. Install bolts (x6), install clutch alignment tool, evenly torque tighten bolts (x6) in a diagonal sequence.
Remove clutch alignment tool.
30. Remove bolts (x2), collect tool (303-1185).
31. Install inspection cover, install and torque tighten bolts (x2).
32. Install engine sump (see Workshop Manual procedure 03.02.CN Pan - Oil Sump - Remove and Reseal With
Engine Removed).
Crankshaft Assembly-Renew
Removal
1. Remove bolts (x2), inspection cover to lower crankcase, remove cover.
2. Install tool (303-1185) to restrain flywheel, install and tighten bolts (x2).
3. Remove bolts (x6), clutch cover to flywheel.
4. Release clutch cover from dowels (x3), remove clutch cover, collect drive plate.
5. Remove and discard bolts (x8), flywheel to crankshaft flange.
6. Remove bolts (x2), collect tool (303-1185).
7. Release flywheel from dowel, remove flywheel.
8 . R e m o v e e n g i n e s u mp ( s e e Wo r k s h o p M a n u a l p ro c e d u re 03.02.CN Pan - Oil Sump - Remove and Reseal With
Engine Removed).
Caution
Do not lubricate engine bedplate retaining bolts.
Caution
Tighten engine bedplate retaining bolts in the sequence shown.
Caution
Do not rotate crankshaft until all engine bedplate
retaining bolts are tightened to specification.
Caution
Engine bedplate retaining bolts must be tightened
within twenty minutes of applying sealant.
A0311328
A0311328
Caution
Do not use any lubricant on cr ankshaft oil seals or seal
protectors. Make sure all co mponents are clean and dry.
Repair Operation Time (ROT)
ItemCode
Crankshaft Assembly-Renew 03.11.CF
WAR NI NG
DO NOT GET USED ENGINE OIL ON YOUR SKIN.
USED ENGINE OIL CAN BE HARMFUL.

Power Conversion (03.11)
Engine (03.00)3-11-6 Workshop Manual May 2007
24. Remove main bearing shells (grooved) from cylinder
block (see Figure 5).
Figure 5
25. Remove main bearing shells (plain) from engine bedplate (see Figure 6).
Figure 6
Installation
1. Clean crankshaft main bearing and connecting rod journals.
2. Clean bearing recess in cylinder block.
3. Clean old sealant from engine bedplate and bearing recesses.
4. Clean bearing shell locations in connecting rods and caps.
5. Select the correct colour coded bearing shells for each connecting rod crankshaft journal.
6. Select the correct colour coded bearing shells for each main bearing journal. 7. Install selected main bearing
shells in cylinder block and
engine bedplate.
8. Install thrust washers in cylinder block.
9. Install selected bearing shells in connecting rods and bearing caps.
10. Lubricate crankshaft journa ls with clean engine oil.
11. Position connecting rods and carefully lower crankshaft into cylinder block.
12. Install crankshaft retaining caps (303-534), install and lightly tighten bolts (x10).
13. Carefully pull each connecting rod into place on crankshaft journals.
14. Install connecting rod bearing caps (x8), install and torque tighten retaining bolts.
15. Remove bolts securing cran kshaft retaining caps (303-
534), remove retaining caps.
16. Apply a 2mm diameter continuous bead of sealant to cylinder block flange ensuring that there are no gaps in
the sealant.
17. Install engine bedplate to cylinder block, install and torque tighten bolts (x34) in the correct sequence.
18. Remove excess sealant from crankshaft rear oil seal aperture and front face of cylinder block.
19. Clean windage tray.
20. Install windage tray, install and torque tighten bolts (x8).
21. Ensure that oil seal protector is positioned correctly and install oil seal onto crankshaft flange.
22. Install tool (303-1189) to crankshaft, position nuts on tool against oil seal.
23. Ensure that oil seal and special are parallel to rear of engine.
24. To install oil seal, tighten nuts alternately on tool (303- 1189) until oil seal correctly seated.
25. Remove special tool from crankshaft.
26. Check that the oil se al is located correctly.
Note: Main bearing shells are
selective by colour code with
plain bearings in bedplate and grooved bearings in cylinder
block
Caution
Use only a plastic scraper when removing old sealant and gaskets from engine components.
A0311334
A0311335
Caution
When assembling connecting rods and connecting rod
bearing caps it is imperative that bearing slots and tangs
be located on the same side of the connecting rods.
Caution
Do not lubricate engine bedplate retaining bolts.
Caution
Tighten engine bedplate retaining bolts in the sequence shown.
Caution
Do not rotate crankshaft until all engine bedplate
retaining bolts are tightened to specification.
Caution
Engine bedplate retaining bolts must be tightened within twenty minutes of applying sealant.
Caution
Do not use any lubricant on cr ankshaft oil seals or seal
protectors. Make sure all co mponents are clean and dry.

Power Conversion (03.11)
Engine (03.00)3-11-12 Workshop Manual May 2007
12. Install piston ring clamp to each piston in turn and install
in its respective cylinder bore. Remove piston ring
clamp (see Figure 19).
Figure 19
13. Lubricate crankshaft journa ls with clean engine oil.
14. Carefully pull each connecting rod into place on each crankshaft journal.
15. Install bearing caps to their relevant connecting rods. Install and torque tighten retaining bolts (x16).
16. Clean windage tray.
17. Install windage tray, install and torque tighten bolts (x8).
18. Clean old sealant from sump flange and engine bedplate.
19. Ensure that sump flange and mating face on engine bedplate are clean and dry.
20. Apply a continuous 3mm diameter bead of RTV sealant to sump flange as recommended.
21. Ensure that there are no gaps in sealant track.
22. Install sump, install and torque tighten bolts (x16) in the correct sequence.
23. Install A/C compressor mounting bracket, install and torque tighten Torx bolts (x4).
24. Lubricate and install new O-ring seals to oil pipes.
25. Install oil pipes in sump, install and torque tighten bolts (x2)
26. Install compressor, install and torque tighten bolts (x4).
27. Connect multiplug to A/C compressor.
28. Install LH and RH HEGO sensor multiplug brackets to sump. Install and torque tighten bolts (x4).
29. Secure harness clips (x6) in sump.
30. Connect multiplug to crankshaft timing sensor.
31. Connect multiplug to engine electric coolant temperature sensor.
32. Connect multiplug to oil pressure sensor.
33. Clean oil scavenge pump and mating face on sump.
34. Install oil pump(s) drive sprocket. 35. Install new oil scavenge pump gasket, align on dowels
(x2).
36. Install chain onto oil scavenge pump sprocket.
37. Install oil scavenge pump, align to dowels (x2), Install
and torque tighten bolts (x3).
38. Install chain onto oil pump drive sprocket.
39. Clean oil pressure pump and mating face on sump.
40. Install new gasket to sump, align to dowels (x2).
41. Position oil pressure pu mp, install chain on pump
sprocket.
42. Install oil pressure pump, align to dowels (x2), Install and
torque tighten bolts (x3).
43. Install chain tensioner, install and torque tighten bolt, remove guide pin.
44. Install crankshaft timing sprocket.
45. Install cylinder head gaskets - engine set (see Workshop Manual procedure 03.01.HW Gasket - Cylinder Head -
Engine Set - Renew Wi th Engine Removed).
Piston-Renew
Removal
1. Remove cylinder head gaskets - engine set (see
Workshop Manual procedure 03.01.HW Gasket -
Cylinder Head - Engine Set - Renew With Engine
Removed).
2. Remove crankshaft timing sprocket from crankshaft.
3. Install guide pin through lower hole on chain tensioner.
4. Remove bolt securing oil pressure pump chain tensioner assembly to engine bedplate (see Figure 1).
Figure 1
Caution
When assembling connecting rods and connecting rod
bearing caps it is imperative that bearing slots and tangs
be located on the same side of the connecting rods.
A0311337
Repair Operation Time (ROT)
ItemCode
Piston-Renew 03.11.CH
WAR NI NG
DO NOT GET USED ENGINE OIL ON YOUR SKIN.
USED ENGINE OIL CAN BE HARMFUL.
A0302274

Power Conversion (03.11)
Engine (03.00)
May 2007 Workshop Manual 3-11-17
12. Install piston ring clamp to piston, install piston assembly
in its cylinder bore. Remo ve piston ring clamp (see
Figure 19).
Figure 19
13. Lubricate crankshaft journal with clean engine oil.
14. Carefully pull connecting ro d into place on crankshaft
journal.
15. Install bearing cap to connecting rod. Install and torque tighten retaining bolts (x2).
16. Clean windage tray.
17. Install windage tray, install and torque tighten bolts (x8).
18. Clean old sealant from sump flange and engine bedplate.
19. Ensure that sump flange and mating face on engine bedplate are clean and dry.
20. Apply a continuous 3mm diameter bead of RTV sealant to sump flange as recommended.
21. Ensure that there are no gaps in sealant track.
22. Install sump, install and torque tighten bolts (x16) in the correct sequence.
23. Install A/C compressor mounting bracket, install and torque tighten Torx bolts (x4).
24. Lubricate and install new 'O' ring seals to oil pipes.
25. Install oil pipes in sump, install and torque tighten bolts (x2)
26. Install compressor, install and torque tighten bolts (x4).
27. Connect multiplug to A/C compressor.
28. Install LH and RH HEGO sensor multiplug brackets to sump. Install and torque tighten bolts (x4).
29. Secure harness clips (x6) in sump.
30. Connect multiplug to crankshaft timing sensor.
31. Connect multiplug to engine electric coolant temperature sensor.
32. Connect multiplug to oil pressure sensor.
33. Clean oil scavenge pump and mating face on sump.
34. Install oil pump(s) drive sprocket.
35. Install new oil scavenge pu mp gasket, align on dowels
(x2). 36. Install chain onto oil scavenge pump sprocket.
37. Install oil scavenge pump, align to dowels (x2), Install
and torque tighten bolts (x3).
38. Install chain onto oil pump drive sprocket.
39. Clean oil pressure pump and mating face on sump.
40. Install new gasket to sump, align to dowels (x2).
41. Position oil pressure pump, install chain on pump sprocket.
42. Install oil pressure pump, align to dowels (x2), Install and torque tighten bolts (x3).
43. Install chain tensioner, install and torque tighten bolt, remove guide pin.
44. Install crankshaft timing sprocket.
45. Install cylinder head gaskets - engine set (see Workshop Manual procedure 03.01.HW Gasket - Cylinder Head -
Engine Set - Renew With Engine Removed).
Additional Piston-Renew (Each)
Removal
1. Mark bearing caps and connecting rods for correct installation.
2. Remove bolts (x2) securing bearing cap to connecting rod, remove bearing cap.
3. Install special tools (303-535) to the connecting rod to prevent damage to crankshaft journal.
4. Carefully push connecting rod/piston assembly upwards and remove from cylinder bore.
5. Remove special tools from connecting rod.
6. Install bearing cap on connecting rod, install and lightly tighten retaining bolts.
7. Remove circlip (x2) securing gudgeon pin in piston and
connecting rod. Remove piston.
Installation
1. Clean cylinder bore.
2. Install piston rings in cylinder bore to a pre-determined depth and measure ring gaps.
3. Remove piston ring set from cylinder bore and install on piston.
4. Clean connecting rod.
5. Install piston on connecting rod in its correct orientation, install circlip(s).
Caution
Install pistons into cylinder block with the ‘arrow’ on the
piston crown facing to the front of the engine.
A0311337
Repair Operation Time (ROT)
WA R N I N G
DO NOT GET USED ENGINE OIL ON YOUR SKIN. USED ENGINE OIL CAN BE HARMFUL.
Caution
Connecting rod bolts are tor que
tightened to yield and
mu st
be replaced.

Power Conversion (03.11)
Engine (03.00)3-11-22 Workshop Manual May 2007
34. Note that piston grade number on crown and thick
flange on connecting rod faces to front of engine on LH
bank (B) (see Figure 16).
Figure 16
Installation
1. Clean cylinder bores.
2. Use an expander and remove and discard piston rings from pistons.
3. Clean pistons.
4. Install new piston rings, (each set), in cylinder bores to a pre-determined depth and measure ring gaps.
5. Remove each piston ring set from cylinder bores and install on pistons
6. Remove connecting rod bearing caps.
7. Install bearings in connecting rods and bearing caps.
8. Lubricate cylinder bores, pistons and rings with clean
engine oil.
9. Install special tools (303-303-535) to the connecting rod to prevent damage to crankshaft journal.
10. Correctly position ring gaps on pistons prior to
installation. 11. Install piston ring clamp to each piston in turn and install
in its respective cylinder bore. Remove piston ring
clamp (see Figure 17).
Figure 17
12. Lubricate crankshaft journa ls with clean engine oil.
13. Carefully pull each connecting rod into place on each crankshaft journal.
14. Install bearing caps to their relevant connecting rods. Install and torque tighten retaining bolts (x16).
15. Clean windage tray.
16. Install windage tray, install and torque tighten bolts (x8).
17. Clean old sealant from sump flange and engine bedplate.
18. Ensure that sump flange and mating face on engine bedplate are clean and dry.
19. Apply a continuous 3mm diameter bead of RTV sealant to sump flange as recommended.
20. Ensure that there are no gaps in sealant track.
21. Install sump, install and torque tighten bolts (x16) in the correct sequence.
22. Install A/C compressor mounting bracket, install and torque tighten Torx bolts (x4).
23. Lubricate and install new O-ring seals to oil pipes.
24. Install oil pipes in sump, install and torque tighten bolts (x2)
25. Install compressor, install and torque tighten bolts (x4).
26. Connect multiplug to A/C compressor.
27. Install LH and RH HEGO sensor multiplug brackets to
sump. Install and torque tighten bolts (x4).
28. Secure harness clips (x6) in sump.
29. Connect multiplug to crankshaft timing sensor.
30. Connect multiplug to engine electric coolant temperature sensor.
31. Connect multiplug to oil pressure sensor.
Caution
Make sure the piston ring gaps are positioned at
different positions opposite th e thrust side of the piston
before installation.
A0311332
Caution
Install pistons into cylinder block with the

Power Conversion (03.11)
Engine (03.00)
May 2007 Workshop Manual 3-11-27
10. Install special tools (303-535) to the connecting rod to
prevent damage to crankshaft journal.
11. Install piston ring clamp to piston, install piston assembly
in its cylinder bore. Remo ve piston ring clamp (see
Figure 16).
Figure 16
12. Lubricate crankshaft journal with clean engine oil.
13. Carefully pull connecting ro d into place on crankshaft
journal.
14. Install bearing cap to connecting rod. Install and torque tighten retaining bolts (x2).
15. Clean windage tray.
16. Install windage tray, install and torque tighten bolts (x8).
17. Clean old sealant from sump flange and engine bedplate.
18. Ensure that sump flange and mating face on engine bedplate are clean and dry.
19. Apply a continuous 3mm diameter bead of RTV sealant to sump flange as recommended.
20. Ensure that there are no gaps in sealant track.
21. Install sump, install and torque tighten bolts (x16) in the correct sequence.
22. Install A/C compressor mounting bracket, install and torque tighten Torx bolts (x4).
23. Lubricate and install new O-ring seals to oil pipes.
24. Install oil pipes in sump, install and torque tighten bolts (x2)
25. Install compressor, install and torque tighten bolts (x4).
26. Connect multiplug to A/C compressor.
27. Install LH and RH HEGO se nsor multiplug brackets to
sump. Install and torque tighten bolts (x4).
28. Secure harness clips (x6) in sump.
29. Connect multiplug to crankshaft timing sensor.
30. Connect multiplug to engine electric coolant temperature sensor. 31. Connect multiplug to oil pressure sensor.
32. Clean oil scavenge pump and mating face on sump.
33. Install oil pump(s) drive sprocket.
34. Install new oil scavenge pu
mp gasket, align on dowels
(x2).
35. Install chain onto oil scavenge pump sprocket.
36. Install oil scavenge pump, align to dowels (x2), Install and torque tighten bolts (x3).
37. Install chain onto oil pump drive sprocket.
38. Clean oil pressure pump and mating face on sump.
39. Install new gasket to sump, align to dowels (x2).
40. Position oil pressure pump, install chain on pump sprocket.
41. Install oil pressure pump, align to dowels (x2), Install and torque tighten bolts (x3).
42. Install chain tensioner, install and torque tighten bolt, remove guide pin.
43. Install crankshaft timing sprocket.
44. Install cylinder head gaskets - engine set (see Workshop Manual procedure 03.01.HW Gasket - Cylinder Head -
Engine Set - Renew With Engine Removed).Piston Ring Set-Additional-Renew (Each)
Removal
1. Mark bearing cap and connecting rod for correct
installation (see Figure 1).
Figure 1
Caution
Install pistons into cylinder block with the ‘arrow’ on the
piston crown facing to the front of the engine.
Caution
Use only a plastic scraper when removing old sealant
and gaskets from engine components.
A0311337
Repair Operation Time (ROT)
WA R N I N G
DO NOT GET USED ENGINE OIL ON YOUR SKIN.
USED ENGINE OIL CAN BE HARMFUL.
A0311329

Power Conversion (03.11)
Engine (03.00)
May 2007 Workshop Manual 3-11-33
34. Note that piston grade number on crown and thick
flange on connecting rod faces to front of engine on LH
bank (B) (see Figure 17).
Figure 17
Installation
1. Clean cylinder bores.
2. Clean connecting rods,
3. Install pistons on connecting rods in their correct orientation, install circlip(s) (see Figure 18)
.
Figure 18
4. Correctly position ring gaps on pistons prior to installation.
5. Remove connecting rod bearing caps.
6. Install bearings in connecting rods and bearing caps.
7. Lubricate cylinder bores, pistons and rings with clean
engine oil.
8. Install special tools (303-535) to the connecting rod to prevent damage to crankshaft journal. 9. Install piston ring clamp to each piston in turn and install
in its respective cylinder bore. Remove piston ring
clamp (see Figure 19).
Figure 19
10. Lubricate crankshaft journals with clean engine oil.
11. Carefully pull each connecting rod into place on each crankshaft journal.
12. Install bearing caps to their relevant connecting rods. Install and torque tighten retaining bolts (x16).
13. Clean windage tray.
14. Install windage tray, install and torque tighten bolts (x8).
15. Clean old sealant from sump flange and engine bedplate.
16. Ensure that sump flange and mating face on engine bedplate are clean and dry.
17. Apply a continuous 3mm diameter bead of RTV sealant to sump flange as recommended.
18. Ensure that there are no gaps in sealant track.
19. Install sump, install and torque tighten bolts (x16) in the correct sequence.
20. Install A/C compressor mounting bracket, install and torque tighten Torx bolts (x4).
21. Lubricate and install new 'O' ring seals to oil pipes.
22. Install oil pipes in sump, install and torque tighten bolts (x2)
23. Install compressor, install and torque tighten bolts (x4).
24. Connect multiplug to A/C compressor.
25. Install LH and RH HEGO se nsor multiplug brackets to
sump. Install and torque tighten bolts (x4).
26. Secure harness clips (x6) in sump.
27. Connect multiplug to crankshaft timing sensor.
28. Connect multiplug to engine electric coolant temperature sensor.
29. Connect multiplug to oil pressure sensor.
Caution
Make sure the piston ring gaps are positioned at
different positions opposite the thrust side of the piston
before installation.
A0311332
A0311333
Caution
Install pistons into cylinder block with the

Power Conversion (03.11)
Engine (03.00)
May 2007 Workshop Manual 3-11-35
4. Install tool (303-1190) into crankshaft front oil seal (see
Figure 1).
Figure 1
5. Tighten centre bolt of tool (303-1190) and withdraw oil seal from timing cover (see Figure 2).
Figure 2
6. Remove seal from special tool.
Installation
1. Clean oil seal aperture in timing cover.
2. Do NOT remove protector from oil seal. 3. Position new oil seal (fitted dry). Install oil seal in timing
cover using tool (303-750) (see Figure 3).
Figure 3
4. Remove crankshaft oil seal protector.
5. Install crankshaft pulley (see Workshop Manual procedure 03.11.CP Pulley Assembly - Crankshaft
Damper - Renew).
6. Lower vehicle on ramp.
7. Battery isolation switch ‘ON’.
Rear Oil Crankshaft Seal-Renew
Removal
1. Remove clutch and flywheel assembly (see Workshop Manual procedure 08.00.AA Clutch and Flywheel
Assembly - Renew).
2. Position tool (303 -1189) to crankshaft flange, screw in alignment bolts (x2) 1.5 turns (only).
3. Use tool and pierce holes (x3) in oil seal through holes in special tool for self-tapping screws
4. Install and tighten self-tapping screws (x3) into oil seal.
5. Tighten centre bolt of tool (303-1189) and withdraw crankshaft oil seal.
6. Remove oil seal from spec ial tool, discard oil seal.
Installation
1. Clean oil seal aperture in cylinder block.
2. Ensure that oil seal protecto r is positioned correctly and
install oil seal onto crankshaft flange.
3. Install tool (303-1189) to crankshaft, position nuts on
tool against oil seal.
Caution
Caution: Make sure the cranks haft front oil seal mating
faces are clean and dry.
Caution
Do not remove the crankshaft front oil seal protector
until the oil seal is correctly installed.
A0311246
A0311246A
Repair Operation Time (ROT)
A0311247

Power Conversion (03.11)
Engine (03.00)
May 2007 Workshop Manual 3-11-37
10. Remove and discard O-ring seal from pulley (see Figure
2).
Figure 2
Installation
1. Clean crankshaft pulley, locking ring and mating face on crankshaft.
2. Lubricate and install new O-ring seal in crankshaft pulley.
3. Install crankshaft pulley, locking ring and new pulley bolt.
4. Torque tighten crankshaft pulley bolt. Remove special tool (303-1185) from crankcase.
5. Install inspection cover to lower crankcase, install and tighten bolts (x2).
6. Install drive belt on pulleys.
7. Install drive belt tensioner, install and torque tighten bolt.
8. Release tensioner and install drive belt onto idler pulley.
9. Install engine assembly (see Workshop Manual procedure 03.00.AA Engi ne Assembly - Renew).
Crankshaft Front Oil Seal-Renew (with
Engine Removed
)
Removal
1. Remove crankshaft pulley (see Workshop Manual
procedure 03.11.DP Pulley Assembly - Crankshaft
Damper - Renew With Engine Removed). 2. Install tool (303-1190) into
crankshaft front oil seal (see
Figure 1).
Figure 1
3. Tighten centre bolt of tool (303-1190) and withdraw oil seal from timing cover (see Figure 2).
Figure 2
4. Remove seal from special tool.
Installation
1. Clean oil seal aperture in timing cover.
2. Do NOT remove protector from oil seal.
Repair Operation Time (ROT)
A0311321
Caution
Make sure the crankshaft front oil seal mating faces are clean and dry.
Caution
Do not remove the crankshaft front oil seal protector
until the oil seal is correctly installed.
A0311246
A0311246A