check engine ASTON MARTIN V8 VANTAGE 2010 Owner's Guide

Power Conversion (03.11)
Engine (03.00)3-11-36 Workshop Manual May 2007
4. Ensure that oil seal and special are parallel to rear of
engine.
5. To install oil seal, tighten nuts alternately on tool (303- 1189) until oil seal correctly seated.
6. Remove special tool from crankshaft.
7. Check that the oil seal is located correctly.
8. Install clutch and flywheel assembly (see Workshop Manual procedure 08.00.AA Clutch and Flywheel
Assembly - Renew).
Cylinder Block-Renew
Removal
1. Remove cylinder head gasket - engine set (see Workshop Manual procedure 03.01.HW Gasket -
Cylinder Head - Engine Set - Renew With Engine
Removed).
2. Remove crankshaft assembly.
3. Remove pistons and connecting rod assemblies from cylinder block.
4. Remove Torx screws (x4) securing engine oil cooling
valves to cylinder block.
5. Remove engine oil cooling valves (x4).
6. Remove bolts (x5) securing water pump to cylinder block. Remove water pump, discard gasket.
7. Remove cylinder block valley cover.
Installation
1. Clean cylinder block valley cover and mating face on cylinder block.
2. Install cylinder block valley cover.
3. Clean engine oil cooling valves.
4. Install engine oil cooling valves in cylinder block.
5. Install and torque tighten Torx screws (x4).
6. Clean connecting rods and piston assemblies.
7. Correctly position ring gaps on pistons prior to installation.
8. Remove connecting rod bearing caps.
9. Install bearings in connecting rods and bearing caps.
10. Lubricate cylinder bores, pistons and rings with clean engine oil.
11. Install special tools (303-535) to the connecting rod to prevent damage to crankshaft journal.
12. Install crankshaft assembly.
13. Install new gasket, water pump, install and torque tighten bolts (x5). 14. Install cylinder head gasket - engine set (see Workshop
Manual procedure 03.01.HW Gasket - Cylinder Head -
Engine Set - Renew Wi th Engine Removed).
Crankshaft Damper Pulley Assembly-
Renew (with Engine Removed)
Removal
1. Remove engine assembly (see Workshop Manual
procedure 03.00.AA Engine Assembly - Renew).
2. Release drive belt tensioner, release drive belt from idler pulley (see Figure 1).
Figure 1
3. Remove bolt securing drive belt tensioner to engine timing cover, remove tensioner.
4. Remove drive belt from pulleys.
5. Remove bolts (x2), inspection cover to lower crankcase, remove cover.
6. Install tool (303-1185) to restrain flywheel, install and tighten bolts (x2).
7. Install thrust button of tool (303 -1186) in crankshaft,
position tool in pulley, secure with bolts (x2). Tighten
centre bolt, withdraw pulley from crankshaft.
8. Collect crankshaft pulley, locking ring and special tool thrust button.
9. Remove special tool from pulley.
Caution
Alternate nut tightening to correctly seat the crankshaft rear oil seal.
Repair Operation Time (ROT)
WAR NI NG
DO NOT GET USED ENGINE OIL ON YOUR SKIN.
USED ENGINE OIL CAN BE HARMFUL.
Repair Operation Time (ROT)
ItemCode
Crankshaft Damper Pulley Assembly-
Renew 03.11.DP
A030553

Power Conversion (03.11)
Engine (03.00)3-11-38 Workshop Manual May 2007
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 pulle y (see Workshop Manual
procedure 03.11.DP Pulley Assembly - Crankshaft
Damper - Renew With Engine Removed).
Crankshaft Rear Oil Seal-Renew (with
Engine Removed
)
Removal
1. Remove engine assembly (see Workshop Manual
procedure 03.00.AA Engi ne Assembly - Renew).
2. Remove bolts (x2), inspection cover to lower crankcase, remove cover.
3. Install tool (303-1185) to restrain flywheel, install and tighten bolts (x2).
4. Remove bolts (x6), clutch cover to flywheel.
5. Release clutch cover from dowels (x3), remove clutch cover, collect drive plate.
6. Remove and discard bolts (x8), flywheel to crankshaft flange.
7. Remove bolts (x2), collect tool (303-1185).
8. Release flywheel from dowel, remove flywheel.
9. Position tool (303-1189) to crankshaft flange, screw in
alignment bolts (x2) 1.5 turns (only).
10. Use tool and pierce holes (x3) in oil seal through holes in special tool for self-tapping screws
11. Install and tighten self-tapping screws (x3) into oil seal.
12. Tighten centre bolt of tool (303-1189) and withdraw crankshaft oil seal.
13. Remove oil seal from special tool, discard oil seal.
Installation
1. Clean oil seal aperture in cylinder block.
2. Ensure that oil seal protector is positioned correctly and install oil seal onto crankshaft flange.
3. Install tool (303-1189) to crankshaft, position nuts on
tool against oil seal.
4. Ensure that oil seal and special are parallel to rear of engine.
5. To install oil seal, tighten nuts alternately on tool (303- 1189) until oil seal correctly seated.
6. Remove special tool from crankshaft.
7. Check that the oil seal is located correctly.
8. Clean flywheel and mating face on crankshaft.
9. Install flywheel, align to dowel on crankshaft flange.
10. Install new bolts (x8), install tool (303-1185) to restrain flywheel. Torque tighten bolts (x8) in the correct
sequence.
11. Clean clutch cover and drive plate.
12. Install clutch assembly on flywheel, align to dowels (x3).
13. Install bolts (x6), install clutch alignment tool, evenly torque tighten bolts (x6) in a diagonal sequence.
Remove clutch alignment tool.
14. Remove bolts (x2), collect tool (303-1185).
15. Install inspection cover, install and torque tighten bolts (x2).
16. Install engine assembly (see Workshop Manual procedure 03.00.AA Engine Assembly - Renew).
Repair Operation Time (ROT)
A0311247
Caution
Do not use any lubricant on cr ankshaft oil seals or seal
protectors. Make sure all co mponents are clean and dry
Caution
Alternate nut tightening to correctly seat the crankshaft rear oil seal.

Engine Management System (03.14)
Engine (03.00)
Issue 5, Janauary 2010 Workshop Manual 3-14-3
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. Secure sufficient lengths of string to HEGO sensor multiplugs for assembly purposes.
5. Loosen LH and RH clamp nuts, catalysts to centre pipes.
6. With assistance, manoeuvre exhaust centre pipe assembly rearwards to release from catalysts.
7. Remove nuts (x3), catalyst to exhaust manifold.
8. Release and support weight of LH catalyst from exhaust manifold.
9. Manoeuvre HEGO sensor leads and remove cable tie. Release HEGO sensor leads from behind heat shield.
Remove string from HEGO multiplugs.
10. Remove catalyst assembly.
11. Remove and discard gasket.
12. Remove HEGO sensors from catalyst.
Installation
1. Clean catalyst, mating joint faces and HEGO sensors.
2. Install and tighten HEGO sensor to catalyst.
3. Apply proprietary exhaust se alant around clamp joints.
4. Install new gasket to exhaust manifold.
5. Position catalyst, secure string (x2) to HEGO multiplugs, feed sensor leads behind heat shield. Install catalyst to
exhaust manifold.
6. Instal land tighten nuts (x3), catalyst to exhaust manifold.
7. Align centre pipe assembly to catalyst, tighten clamp
nuts to.
8. Remove string (x2), conne ct multiplugs (x2), HEGO
sensors.
9. Install rear exhaust silencer (refer to Workshop Manual procedure 09.00.KA Silencer and Bypass Valve
Assembly - Remove for Access and Refit).
10. Lower vehicle on ramp.
Left Side Powertrain Control Module
(PCM) (Coupe Only) - Remove and
Install
Remove
1. Disconnect the ba ttery ground cable.
2. Remove the wheel and tyre. (refer to Workshop Manual procedure 04.04.EC - Wheel and Tyre)
3. Remove the six rear screws that attach the wheel-arch liner to the body.
4. Remove the rear screw that attaches the wheel-arch liner to the body.
5. Turn the steering fully to the right.
6. Move the wheel arch liner to get access to the Powertrain Control Module (PCM).
7. Disconnect the electrical connector from the direction
indicator.
8. Release the four fi r-tree clips that attach the wiring
harness for the direction indi cator and the screen wash
system.
9. Release the two fir tree clips that attach the wiring harness for the PCM.
10. Remove the three bolts that attach the PCM bottom bracket and PCM to the PCM top bracket.
11. Disconnect the three electrical connectors from the PCM.
12. Remove the PCM.
Install
1. Put the PCM in position.
2. Connect the three electrical connectors to the PCM.
3. Align the PCM to the top bracket.
4. Align the bottom bracket to the PCM.
5. Install and tighten the three bolts that attach the PCM bottom bracket and PCM to the PCM top bracket.
6. Install the two fir tree clips that attach the wiring harness for the PCM.
7. Attach the four fir-tree cl ips that attach the wiring
harness for the direction indi cator and the screen wash
system.
8. Connect the electrical connector to the direction indicator.
9. Put the wheel-arch liner into the correct position.
10. Install and tighten the rear screw that attaches the wheel-arch liner to the body.
11. Install and tighten the six rear screws that attach the wheel-arch liner to the body.
12. Move the steering to the centre position.
13. Connect the battery ground cable.
14. Install the wheel and tyre. (04.04.EC - Wheel and Tyre)
15. Connect AMDS.
16. Use AMDS to do a test of the PCM. (00.06.AD - AMDS Operation Check)
WA R N I N G
THE EXHAUST SYSTEM WILL BE VERY HOT AFTER OPERATION. LET THE EXHAUST SYSTEM COOL
BEFORE YOU DO WORK. IF YOU DO NOT, SEVERE
INJURY CAN OCCUR
Repair Operation Time (ROT)

Front Suspension (04.01)
Suspension (04.00)4-1-4 Workshop Manual November 2008
RH/LH Lower Front Suspension Arm
Assembly - Renew
Removal
1. Raise vehicle on ramp.
2. Remove road wheel(s).
3. Remove nut/washer securing anti-roll bar link to lower suspension, release link from arm.
4. Remove nut/bolt securing damper to lower suspension arm, release damper from mounting.
5. Remove nut securing lower suspension arm ball-joint to vertical link.
6. Install tool (204 - 523) ba ll-joint remover and release
lower suspension ball-joi nt from vertical link.
7. Mark fitted positions of cam washers on lower suspension arm inner fixings to aid assembly purpose.
8. Remove nuts/bolts, cam washers (x2), securing lower suspension arm to subframe.
9. Release/remove lower suspension arm from subframe and vertical link.
Installation
1. Clean lower suspension arm and mating faces on vertical link and subframe
2. Install lower suspension arm in subframe.
3. Install cam washers, bolts/nuts (x2). Align cam washers to marks. Do not torque tighten at this stage.
4. Install lower suspension arm ball-joint in vertical link. Install and torque tighten nut.
5. Align damper to mounting, install bolt/nut. Do not torque tighten at this stage.
6. Install anti-roll bar link, install washer/nut. Do not torque tighten at this stage.
7. Final tightening of suspen sion components must be
carried out with the suspensi on arms at normal ride
height.
8. Install road wheel(s).
9. Lower vehicle on ramp.
10. Torque tighten suspension nuts/bolts.
11. 4 wheel alignment - check/adjust (see Workshop Manual procedure 04.00.AD 4 Wheel Alignment -
Check and Adjust).
RH/LH Upper Front Suspension Arm
Assembly - Renew
Removal
1. Raise the vehicle and make it safe.
2. Remove the road wheel for the applicable suspension arm.
3. Disconnect the electrical connector from the ABS sensor.
4. Release the three sensor harness clips from the upper suspension arm and the vertical link.
5. Remove the two Torx screws that attach the engine cross brace to the mounting.
6. Remove the two nuts and two bolts that attach the upper suspension arm to the body.
7. Release the suspension arm from the body.
8. Remove the three nuts that attach the damper top mounting.
9. Remove the mounting for the engine cross brace.
10. Remove the nut and bolt that attaches the damper to its lower mounting.
11. Remove spring/damper assembly.
12. Remove the nut that attaches the ball-joint for the upper suspension arm to the vertical link.
13. Install tool (204 - 523 - ball-joint remover) and release the ball-joint from vertical link.
14. Remove the upper suspension arm assembly.
Installation
1. Clean the upper suspension arm and the mating faces on the body and the vertical link.
2. Install the upper suspension arm to vertical link. Install the nut but do not torque tighten at this step.
3. Install spring/damper assembly.
4. Install the cross-brace support.
5. Install the three nuts but do not torque tighten at this step.
6. Align the damper to the lower mounting, install bolt/nut. Do not torque tighten at this step.
7. Put the upper suspension arm in positionon the body.
8. Install bolts and nuts but do not torque tighten at this step.
9. Connect the electrical connector to the ABS sensor.
Repair Operation Time (ROT)Repair Operation Time (ROT)
ItemCode
Upper Front Suspension Arm
Assembly-Renew RH
04.01.AE
Upper Front Suspension Arm
Assembly-Renew LH
04.01.AF
Caution
Be carefulthat you do not damage the ball-joint rubber
boot when you use the special tool.

Road Wheels and Tyres (04.04)
Suspension (04.00)
May 2007 Workshop Manual 4-4-5
Road Test
A tyre vibration diagnostic proc edure always begins with a road test. The road test and customer interview (if available)
will provide much of the information neede d to find the source of a vibration.
During the road test, drive the vehicle on a road that is smoot h and free of undulations. If vibration is apparent, note and
record the following:
• The speed at which the vibration occurs
• What type of vibration occurs in each speed range
• How the vibration is affected by changes in the following types of vibration-sensitivity:
Torque Sensitive - This means that the condition may be improved or made worse by accelerating, decelerating, coasting,
maintaining a steady vehicle speed or applying engine torque.
Vehicle Speed Sensitive - This means that the vibration always occurs at the same vehicle speed and is not affected by
engine torque, engine speed or the transmission gear selected.
Engine Speed Sensitive - This means that the vibration occurs at varyin g vehicle speeds when a different transmission
gear is selected. It may sometimes be isolated by increasing or decreasing engine speed with the transmission in NEUTRAL
or by stall testing with the transmission in gear. If the condition is engine speed sensitive, the cause is probably not relate d
to the tyres.
If the road test indicates that there is tyre whine, but no sh ake or vibration, the noise originates with the contact between
the tyre and the road surface.
A thumping noise usually means that the tyre has a flat or soft spot making a noise as they slap the roadway. Tyre whine
may be distinguished from axle noise. Tyre whine remains the same over a range of speeds.
Symptoms
SymptomPossible Source(s):Action(s)
Tyres show excess wear on
edge of treads Tyres under-inflated Correct pressure to specification.
Vehicle overloaded Correct as required.
Tyres show excess wear on
edge of treads (having the
correct tyre pressures) Incorrect toe setting Set to specification.
Tyres show excess wear in
center of tread Tyres over-inflated Correct pressure to specification.
Other excessive tyre wear
problems Incorrect tyre pressure Correct pressure to specification.
Incorrect tyre and wheel usage Install correct tyre and wheel combination.
Geometry out of alignm
ent Check and adjust.
Loose, worn or damaged suspension
components Inspect, repair or install new suspension
components as necessary.
Wheel and tyre assembly out of
balance Balance wheel and tyre assembly.
Excessive lateral or radial runout of
wheel or tyre Check, repair or install a new wheel or tyre as
necessary.
Wheel mounting is difficult Incorrect application or mismatched
parts, including wheel studs and wheel
nuts. Corroded, worn or damaged parts Clean or install new parts.
Wobble or shimmy affecting
wheel runout Damaged wheel (eventually damaging
wheel bearings and causing uneven
tyre wear) Inspect wheel rims for damage and runout.
Install a new wheel rim as necessary.
Excessive vibration, rough
steering or severe tyre wear Loose or incorrect attaching parts Tighten or install new parts.

Road Wheels and Tyres (04.04)
Suspension (04.00)4-4-6 Workshop Manual May 2007
Ty r e D a m a g e
Vehicle vibrations Tyres and wheels mismatched Install correct tyre and wheel combination.
Inflation pressure too high or too lo w Correct pressure to specification
Uneven tyre wear Refer to Diagnosis and Testing .
Out-of-balance wheel, tyre, wheel hub
or disc assembly Determine the out-of-balance component and
balance or install a new part.
Damaged or distorted wheel from road
impact hazard or incorrect handling Install a new wheel.
Excessive radial runout Install a new wheel or tyre. Check for incorrect wheel and tyre specifications.
Excessive lateral runout Install a new wheel or tyre.
Incorrectly seated tyre Remount the tyre.
Loose wheel mountings - damaged
wheel studs, wheel nuts, worn or
broken wheel hub face or foreign
material on mounting faces Tighten or install new parts. Clean mounting
surfaces.
Defective wheel bearings Install a new bearing set.
Brake disc imbalance
Water in tyres Remove water.
Loose engine or transmission mounts Install new mount nuts / install new mounts.
Incorrect front end alignment Align front end.
Loose or worn driveline or suspension
parts Repair or install new parts.
Excessive driveshaft runout or
imbalance Install a new driveshaft.
Worn or damaged flexible drive joint Install a new driveshaft.
Damaged wheel hub stud
threads Sliding wheel across the wheel studs
during installation. Loose wheel nuts
Install new wheel studs.
Broken wheel studs Loose or over tightened wheel nuts Install new wheel studs.
Corrosion and contamination
streaks from the wheel hub
wheel stud holes Loose wheel nuts Check complete assembly. Install new parts.
Damaged wheel nuts Loose wheel assembly Install new wheel nuts.
Over-tightened wheel nuts Install new wheel nuts.
Frozen wheel nuts Corrosion or galling If corrosion is light, wire brush away corrosion.
If corrosion is excessive install new wheel studs
and wheel nuts.
SymptomPossible Source(s):Action(s)
SymptomDescription
Age Deterioration Cracking and crazing of the tread and side wall rubber, sometimes accompanied by carcass
deformation. An indication that the tyres have been in service for a very long time.
Neglected Cut Damage through accidental cuts or penetrations will extend in use due to continued flexing and /
or ingress of moisture and road matter.
Impact Fracture Resultant damage from impact fractures is not always visible externally and, therefore, as a safety
precaution the tyre should be removed and examined.
Casing fracture caused by severe localized impact through driving over kerbs, hitting potholes
and / or objects in the road.
A double fracture caused by crushing the side wall of the tyre between an object and the rim
flange.
In both instances, such damage can lead to sudd en and dangerous tyre deflation some time after
the impact occurred.

Manual Transmission (07.03)
Transmission (07.00)
Issue 5, January 2010 Workshop Manual 7-3-33
43. Install the tunnel reinforcement plate.
44. Install and torque the eight bolts that attach the tunnel reinforcement plate to the body.
45. Install floor heatshield.
46. Install and tighten the four bolts that attach the floor heat shield to the body.
47. Install the exhaust front mount.
48. Clean the component mating faces.
49. Apply an applicable sealant to the component mating faces.
50. Install the exhaust centre pipe.
51. Install and tighten the four bolts that attach the exhaust centre pipe to the exhaust front mount.
52. Put the clamps into position on the exhaust pipes.
53. Loosely install the four bolts that attach the exhaust centre pipe to the rear silencer.
54. Align the exhaust assembly.
55. Tighten the two clamps that attach the exhaust centre pipe to the catalytic converters.
56. Install the cross brace.
Figure 24
57. Install and torque the four bolts that attach the cross brace to the rear subframe.
Figure 25
58. Remove the strap that attaches the vehicle to the lift.
59. Lower the vehicle until the wheels are approximately 10 mm above the ground.
60. Connect the battery ground cable.
61. Bleed the clutch system.
62. Use AMDS to do an ASM self-tune.
63. Start the engine, select first gear and allow the wheels to turn for 10 seconds.
64. Lift the vehicle.
65. Remove the fill plug for the transaxle oil.
66. Make sure that the transaxle oil is level with the opening for the transaxle oil. Add more oil if necessary.
67. Install and tighten the fill plug for the transaxle oil.
68. Do a check of the ASM fluid level.
69. Install the rear undertray (refer to Workshop Procedure 01.02.PB - Rear Undertray)
Removal
1. Position vehicle on ramp.
2. Remove rear undertray (see Workshop Manual procedure 01.02.PB Undertray - Rear - Renew).
3. Position container to collect transaxle oil.
4. Remove transaxle drain plug and drain oil.
WA R N I N G
THE EXHAUST CENTRE PIPE IS HEAVY. GET THE AID
OF ONE MORE PERSON
TO DO THE STEP THAT FOLLOWS.
Repair Operation Time (ROT)

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)

Fuel Tank and Lines (10.01)
Fuel (10.00)
May 2007 Workshop Manual 10-1-3
Fuel Tank
The fuel tank incorporates a single filler neck and check valve, internal fuel pump, internal fuel filter, a sender unit and an
‘on board refuelling vapour recovery’ system.
Fuel Pumps

)XHO3XPS
The modular fuel pump is immersed in the base of the fuel
tank. The pump can deliver up to 150 litres/hour. The in-
tank fuel line connects to the external line using a quick-fit
connector in the base of the fuel tank. During normal running, pressu
rised fuel from each fuel
pump passes from the tank, through an 3 micron in-tank fuel
filter to one of the two fuel rails on the engine.
Fuel temperature is measured on the primary fuel rail. If fuel
temperature becomes excessive, the fuel pressure is
increased to prevent fuel vaporisation (boiling).
Fuel pressure is measured by sensors on each fuel rail. The
fuel pressure to each rail is regulated as required by
continuously changing the run speed of the associated fuel
pump. Maximum pressure in the system is limited to 5.3 bar
by in-tank pressure regulators.
A constant head of fuel is maintained in the fuel pump
modules to ensure that the pumps cannot run dry in a ‘low
fuel’ situation.

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+LJK3UHVVXUH)HHG IURP5+63XPS )LOOHU1HFN
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Steering Gear (11.01)
Steering (11.00)
Issue 5, January 2010 Workshop Manual 11-1-3
Vehicle tends to pull
to one side when
driven on a level
surface. Incorrect tyre pressure. Adjust tyre pressure.
Incorrect tyre size.
Different tyre or tread type.
New tyre as required.
Vehicle is unevenly or excessively loaded. Adjust load evenly.
Incorrect toe adjustment. Adjust as required.
Damaged front or rear suspension
components. New suspension components.
Steering gear valve effort out of balance. Shift transmission into neutral while driving at no more than 30 miles/hour (50 km/h) and turn the
ignition to position I (engine ‘Off’-coasting).
a. If the vehicle does not pull to one side with the
engine off, install a new steering gear.
b. If the vehicle drifts with the engine off, ‘cross switch’ the front wheel assemblies.
Test at low speed due to directional tyres.
a. If the vehicle pulls to the opposite side, switch the wheels that were on the rear to the same
side on the front.
b. If the vehicle pull direction is not changed, check the front suspension components and
toe adjustments.
Check front and rear brakes for correct
operation. Adjust as required.
Check for bent rear suspension components
and for damaged coil springs in the front
suspension. New rear suspension components.
Check the rear suspension for loose or worn
suspension components. Tighten.
New components.
Incorrect underbody alignment. Check underbody alignment.
Feedback (whining
or knocking noises
in the steering gear)
Condition where
roughness is felt in
the steering wheel by
the driver when the
vehicle is driven over
rough surfaces. Loose or worn tie-rods. New steering gear.
Steering gear bolts loose or damaged. Tighten.
New bolts.
Loose suspension bushing , bolts or ball joints. Tighten.
New components.
Damaged steering column.
Loose Column bolts. New steering column.
Tighten bolts.
Power steering
pump or reservoir
leaks Overfilled system. Correct fluid level.
Damaged fluid cap. New fluid cap.
Loose or damaged hose fittings. Tighten.
New hose.
Leakage at power steering pump. New power steering pump.
Poor returnability of
the steering Incorrect tyre pressure. Check
and adjust tyre pressure.
Incorrect tyre size or ty pe. New tyre as required.
Steering column universal joints binding . New steering column.
Steering column shaft floor seal may be torn
and fouling I-shaft. New floor seal as required.
Binding or damaged tie-rods. New steering gear.
Damaged or worn front suspension
components. New front suspension components as required.
Incorrect toe adjustment. Adjust as required.
SymptomPossible CauseAction