maintenance ASTON MARTIN V8 VANTAGE 2010 Owner's Guide
[x] Cancel search | Manufacturer: ASTON MARTIN, Model Year: 2010, Model line: V8 VANTAGE, Model: ASTON MARTIN V8 VANTAGE 2010Pages: 947, PDF Size: 43.21 MB
Page 224 of 947
Subframes (02.03)
Frame and Mounting (02.00)
2-1-2 Workshop Manual May 2007
Frame and Mounting (02.00)
Subframes (02.03)
Specifications
Maintenance
Front Subframe-Renew
Removal
1. Switch battery isolation switch ‘OFF’.
2. Raise vehicle on ramp.
3. Remove RH wheel arch liner (see Workshop Manual procedure 01.02.GB Wheel Arch Liner - Front - RH -
Renew).
4. Remove LH wheel arch liner (see Workshop Manual procedure 01.02.FB Wheel Arch Liner - Front - LH -
Renew)
5. Remove road wheel/s.
6. Remove front spring/damper assemblies (see Workshop Manual procedure 04.03.AA Spring and Damper
Assembly - Front Pair - Renew).
7. Remove nuts (x2) from track rod ends to vertical link.
8. Using special tool 204-523, release track rod end from vertical link.
9. Disconnect ABS sensor multiplugs then release sensor harness clips (x6) from upper suspension arm and
vertical link.
10. Disconnect brake pad wear sensor multiplug then release sensor harness clips (x2) from upper suspension
arms. 11. Remove Allen bolts (x4) from brake callipers to vertical
link and tie callipers aside.
12. Remove Torx screws (x4) from brake disc to hub and remove brake disc.
13. Remove anti-roll bar links nuts (x2) and washers (x2).
14. Remove ride height sensor link nut and bolt from lower
suspension arm (see Fig. 1).
15. Mark lower arm bolt and cam washer positions (to retain
geometry).
16. Remove nuts and bolts (x4) and cam washers (x2) from lower suspension arms to subframe (See Fig. 2).
17. Remove nuts and bolts (x4) from upper suspension arm to body.
18. With assistance, remove suspension assemblies.
19. Install engine lifting bracket to LH side of engine using special tool 303-749.
20. Remove EGR valve.
21. Install engine lifting bracket to RH side of engine using special tool 303-749.
Torque Figures
DescriptionNmIb/ft
Subframe to Front Structure 105-125 77.5-92.5
Subframe to Body 105-125 77.5-92.5
Engine Mounts 47 35
Steering Rack 115 85
Torque tube (rear) 43-57 32-42.5
Spring and Damper top mounting
(rear) 85 63
Rear subframe to Body 175 129.5
Rear subframe reinforcement plates 62 46
Repair Operation Time (ROT)
Warning
When raising the vehicle on a 'two post' ramp, ensure
that the rear end of the vehi cle is securely strapped to
the ramp. Failure to strap th e rear of the vehicle down
may lead to the vehicl e falling off the ramp.
Fig. 1
Fig. 2
Page 233 of 947
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
Page 234 of 947
3-0-2 Workshop Manual Issue 5, January 2010
Drive Belt-Renew ...................................................5-1
Engine Drive Belt and Bracket Assembly Oil Pump
Tensioner-Renew ...................................................5-1
Idler Pulley-Renew .................................................5-2
Engine Drive Belt Idler Assembly-Renew ................5-2
Engine Cranking System (03.06) ........................... 3-6-1 Maintenance ...........................................................6-1 Starter Motor-Renew ..............................................6-1
Ignition System (03.07) ......................................... 3-7-1 Maintenance ...........................................................7-1 Coil Assembly-Engine Set - LH-Renew ....................7-1
Emission Control (03.08) ...................................... 3-8-1 Maintenance ...........................................................8-1 Vacuum Outlet Hose Assemb ly-Renew ..................8-1
Secondary Air Injection Pump Tube-Renew............8-1
Vacuum System Reservoir and Bracket Assembly
- Renew .................................................................8-1
Oil Tank Breather Hose-Renew ..............................8-1
Air Cleaner to Rocker Cover Hose-Renew ..............8-1
Oil Separator Tube Assembly-Renew ......................8-1
Oil Separator Assembly-Renew...............................8-2
Emissions Separator Hose-Renew ...........................8-2
Secondary Air Injection Pump and Bracket
Assembly-Renew ....................................................8-2
PCV Valve Assembly-Renew ...................................8-2
Crank Vent Hose-Renew ........................................8-3
Exhaust Valve to Exhaust Manifold Tube Assembly
- Renew .................................................................8-3
Oil Separator to Inlet Manifold Hose- Renew .........8-3
EGR Module-Renew...............................................8-3
Valve Train (03.09)................................................ 3-9-1 Specifications ..........................................................9-1
Maintenance ...........................................................9-1 Left Side Timing Chain Arm Assembly - Remove
and Install ..............................................................9-1
Right Side Timing Chain Arm Assembly - Remove
and Install ..............................................................9-8
RH/LH Secondary Tensioner Assembly - Remove
and Install ............................................................9-14
Right and Left Intake Camshaft - Remove
and Install ............................................................9-15
Right and Left Exhaust Camshaft - Remove
and Install ............................................................9-17
RH/LH Secondary Timing Chain-Renew ...............9-18
RH/LH Secondary Tensioner Assembly-Renew
(with Engine Removed).........................................9-19
RH/LH Intake Camshaft Renew With Engine
Removed .............................................................9-20
RH/LH Exhaust Camshaft-Renew (with Engine
Removed) ............................................................9-22
RH/LH Secondary Timing Chain-Renew (with
Engine Removed) .................................................9-24
RH/LH Intake Camshaft Sprocket and Housing Assembly-
Renew......................................................................9-25 Left Side Primary Chain - Re move and Install).......9-26
RH/LH Intake Camshaft Sprocket and Housing
Assembly-Renew (with Engine Removed) .............9-29
Engine Sealing (03.10) ........................................ 3-10-1 Specifications ........................................................10-1 Maintenance ......................................................... 10-1
Engine Timing Cover - Renew .............................. 10-1
Left Side Cam Cover - Remove and Install ............ 10-4
Left Side Cam Cover Gasket - Renew ................... 10-5
Right Side Cam Cover Gasket - Renew ................. 10-6
Cylinder Head Gasket - Renew (Engine Set) ......... 10-6
Right Side Cam Cover - Remove and Install .......... 10-9
Cam Cover - Vehicle Set - Remove and Install .... 10-10
Engine Timing Cover- Renew (with Engine
Removed) .......................................................... 10-11
John Guest Cartridge in the Engine Timing Cover
- Repair .............................................................. 10-14
Power Conversion (03.11) ...................................3-11-1 Maintenance ......................................................... 11-1 Connecting Rod Bearing-Renew (Engine Set) ........ 11-1
Crankshaft Main Bearing-Renew (Engine Set)........ 11-1
Crankshaft Assembly-Renew................................. 11-4
Piston-Renew (Engine Set) .................................... 11-7
Piston-Renew ..................................................... 11-12
Additional Piston-Renew (E ach) .......................... 11-17
Piston Ring-Renew (Engine Set) .......................... 11-18
Piston Ring-One Piston Se t-Renew ..................... 11-23
Piston Ring Set-Additional -Renew (Each) ............ 11-28
Connecting Rod-Renew (Engin e Set) .................. 11-29
Crankshaft Damper Pulley Assembly-Renew ....... 11-34
Crankshaft Front Oil Seal-R enew ........................ 11-35
Rear Oil Crankshaft Seal-Renew ......................... 11-36
Cylinder Block-Renew........................................ 11-36
Crankshaft Damper Pulley Assembly-Renew
(with Engine Removed) ...................................... 11-37
Crankshaft Front Oil Seal-Renew (with
Engine Removed) ............................................... 11-37
Crankshaft Rear Oil Seal-Renew (with
Engine Removed) ............................................... 11-38
Air Charging (03.12) .......... ..................................3-12-1
Maintenance ......................................................... 12-1 Clean Air Duct - Remove and Install ..................... 12-1
Engine Air Filter - Remove and Install ................... 12-1
Engine Air Cleaner Assembly - Remove
and Install ............................................................ 12-2
Evaporative Emissions (03.13 ) .............................3-13-1
Description ........................................................... 13-1 System Operation ................................................ 13-1
Engine Management System (03.14) ...................3-14-1 Maintenance ......................................................... 14-1 Right Engine Control Module - Renew.................. 14-1
LH Front Lower Heated Exhaust Gas Oxygen
(HEGO) Sensor - Renew....................................... 14-1
LH Front Upper Heated Exhaust Gas Oxygen
(HEGO) Sensor - Renew....................................... 14-1
RH Front Upper Heated Exhaust Gas Oxygen
(HEGO) Sensor - Renew....................................... 14-2
RH Rear Lower Heated Exhaust Gas Oxygen
(HEGO) Sensor - Renew....................................... 14-2
Left Side Powertrain Control Module (PCM)
(Coupe Only) - Remove and Install....................... 14-3
Left Side Powertrain Control Module (PCM)
(Roadster Only) - Remove and Install.................... 14-4
Page 235 of 947
Issue 5, January 2010 Workshop Manual 3-0-3
Throttle Control (03.16) ...................................... 3-15-1Description ........................................................... 15-1Motorised Throttles .............................................. 15-1
Foot Operated Control (03.18) ............................ 3-16-1 Maintenance ......................................................... 16-1Throttle Pedal Assembly-Renew ........................... 16-1
Page 237 of 947
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 #
Page 253 of 947
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
Page 276 of 947
Lubrication System (03.02)
Engine (03.00)3-2-2 Workshop Manual Issue 5, Janauary 2010
Specifications
Engine Oil Specification
Maintenance
Oil Pressure Pump to Sump Gasket -
Renew
1. Remove crankshaft timing chain sprocket (refer to Workshop Manual procedure 03.09.AK Sprocket -
Crankshaft - Renew).
2. Install guide pin through lower hole on chain tensioner. 3. Remove bolt that attaches
the oil pressure pump chain
tensioner assembly to engine bedplate (refer to Figure
1).
4. Remove tensioner assembly.
5. Remove bolts (x3) that attach the oil pressure pump to sump.
6. Release chain from oil pres sure pump sprocket, remove
oil pump.
7. Remove and discard oil pressure pump gasket.
Installation
1. Clean oil pressure pump and mating face on sump.
2. Install new gasket to sump, align to dowels (x2).
3. Position oil pressure pump, install chain on pump sprocket.
4. Install oil pressure pump, align to dowels (x2), Install and torque tighten bolts (x3).
5. Install chain tensioner, install and torque tighten bolt, remove guide pin.
6. Install crankshaft timing chain sprocket (refer to Workshop Manual procedure 03.09.AK Sprocket -
Crankshaft - Renew).
Oil Pump Chain - Renew
Removal
1. Remove oil pressure pump gasket (refer to Workshop Manual procedure 03.02.AG Gasket - Oil Pressure
Pump to Sump - Renew)
Engine oil
Europe/Aus/USA Castrol Edge Sport 10W-60
To achieve the required high performance of synthetic
lubricants, do not mi x with mineral oils.
Capacity Europe (Litres)UK
(Pints)USA
(Qts.)
Full System 13 23 11
Service Fill 10 18 9
Torque Figures
DescriptionNmlb/ft
Oil filter 15 - 18 11-13
Sump plug 20 - 26 15-19
Sump bolts 20 - 22 15-16
Oil delivery pump bolts 19 - 23 14-17
Oil scavenger pump bolts 19 - 23 14-17
Oil scavenger filters 11 - 13 8-10
Oil temperature sensor 16 - 24 12-17
Oil pressure switch 11 - 15 8-11
Oil pump tensioner bracket 11 - 13 8-10
10W-60
AuthorityStandard
API SL/CF
ACEA A3/B3/B4
Oil 10W-60 has both API and ACEA and therefore meets
more demanding tests than eith er API or ACEA oils alone.
Repair Operation Time (ROT)
Figure 1
Repair Operation Time (ROT)
ItemCode
Oil Pump Chain-Renew 03.02.AJ
A0302274
Page 296 of 947
Cooling System (03.03)
Engine (03.00)3-3-2 Workshop Manual Issue 5, Janauary 2010
cooling system. No manual bleed points are provided on the
system.
The coolant reservoir should be full when the coolant system
is cold.
Engine Oil Cooler
The oil temperature is contro lled by an air/oil cooler
mounted at the front of the car. Engine oil is removed from
the dry sump, with the scavenge pump. The oil is routed to
a temperature controlled thermostat which controls the
directional flow of the oil. With the thermostat closed the oil
is routed directly to the oil tank. When the thermostat starts
to open (at 105°C) the oil is routed via the air/oil cooler
before entering the tank.
Specifications
Torque Figures
Maintenance
Coolant-Drain/Fill
1. Raise vehicle on ramp.
2. Remove front undertray (refer to Workshop Manual procedure 01.02.NB Undertray - Front - Renew).
3. Position suitable container to collect coolant.
4. Remove pressure cap from coolant reservoir.
5. Remove drain plug from radiator, allow coolant to drain.
6. Installation
7. Clean radiator drain plug.
8. Install and tighten drain plug.
9. Remove drain container.
10. Install front undertray (refer to Workshop Manual procedure 01.02.NB Undertray - Front - Renew).
11. Lower vehicle on ramp.
12. Fill cooling system with specified coolant mix to maximum level in coolant reservoir.
Antifreeze Mix
50% OAT coolant/50% water
Pressure Cap 150kpa
Leakage Rates 30cm/min. 150-180kpa
60xcm/min. 10kpa
Up to 75kpa @ 150cm/h
Water Pump Pumps 4ltr/min. @ 1000rpm
Pumps 240ltr/min. @ 7000rpm
Thermostat Opens between 86°C - 90°C (186.8°F -
194°F)
Fully open at 102°C
The anti-freeze is un ique and cannot be mixed with other
anti-freeze solutions. The OAT coolant/water mixture has a
life of 150,000 miles or 5 years (which ever comes first).
Description Nm. Ib/ft
Condenser A/C pipes 8-10 6-8
Thermostat Housing 8-12 6-9
Thermostat housing support bracket 23-27 17-20
Water pump 23-27 17-20
Water pump pulley 23-27 17-20
Oil Cooler 50 36
Caution
‘Spring-band’ clips
‘Spring-band’ clips must be installed as detailed below:
All coolant hoses and spigots must be de-greased before assembly.
Repair Operation Time (ROT)
ItemCode
Coolant-Drain-Fill 03.03.AD
WAR NI NG
DO NOT REMOVE THE PRESSURE CAP WHEN THE
COOLANT IS HOT. ALLOW TIME FOR THE COOLANT /
ENGINE TO COOL. TAKE PARTICULAR CARE TO AVOID BURNS FROM THE COOLING SYSTEM.
03-03-002
3
2
4
Coolant Hose SpigottAlignment Marks
Page 308 of 947
Fuel Charging System (03.04)
Engine (03.00)3-4-2 Workshop Manual May 2007
Maintenance
Fuel Rails - 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 Control Module - RH Renew).
9. Remove battery lead (1x nu t 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 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 bracket (nuts x2 and bolts x2).
23. Disconnect EGR vac 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 qu ickfits (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).
44. Remove bolts (x2) bracket to manifold (rear).
45. Move manifold (2x people) forward, remove bolt for purge line T-clip, remove manifold.
46. Remove gaskets and clean mating faces.
Removal - Manifold Parts
47. Remove Injector to rail clips (x8) (see Figure 1).
Figure 1
48. Remove fuel rail (bolts x4).
Installation
1. Install clips and new O-rings to injectors.
2. Install fuel rail (bolts x4).
Repair Operation Time (ROT)
WAR NI NG
THE INTAKE MANIFOLD IS HEAVY. TO AVOID
PERSONAL INJURY OR DAMAGE TO THE INTAKE MANIFOLD, INTAKE MANIFOLD REMOVAL /
ISTALLATION IS A TWO PERSON OPERATION.
A030113
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Engine Cranking System (03.06)
May 2007Workshop Manual 3-6-1
Engine (03.00)
Engine Cranking System (03.06)
Maintenance
Removal
1. Remove RH exhaust manifold (see Workshop Manual
procedure 09.00.CA Manifold - Exhaust - RH - Renew).
2. Switch battery isolation switch ‘OFF’.
3. Remove battery cable from starter motor.
4. Disconnect solenoid multiplug from starter motor (see Figure 1).
Figure 1
5. Remove starter motor bolts (x2) (see Figure 2).
Figure 2
Installation
1. Install starter motor bolts (x2).
2. Connect solenoid multiplug to starter motor.
3. Install battery cable from starter motor.
4. Switch battery isolation switch ‘ON’. 5. Install RH exhaust manifold (see Workshop Manual
procedure 09.00.CA Manifold - Exhaust - RH - Renew).
Repair Operation Time (ROT)