BATTERY SYSTEM ASTON MARTIN V8 VANTAGE 2010 Service Manual

Convertible Roof (01.17)
Body System (01.00)
May 2007 Workshop Manual 1-12-63
15. Remove harness/pipe retaining clips (x3) RH/LH (see Figure 11).
16. Remove pipe from vehicle.
Installation
1. Check oil level and top-up if necessary by removing
reservoir end plug with pump in upright position, add
small quantity of oil replace plug and re-check level (see
Figure 1).
2. Install pipe to approximate route on vehicle.
3. Clean pipe and install pipe to pump then slide retaining plate into place and tighten screws (pipes and locations
are numbered).
4. Clean pipe, connect to cylinder and secure clip.
5. Install cable ties securing pipes and wires to cylinder.
6. Install harness/pipe retaining clips.
7. Position tonneau liner to body and install clips.
8. Install pump casing and secure velcro. 9. Install pump and casing under tonneau onto location
posts.
10. Install cylinder pivot brack et and connect cylinder to
bracket.
11. Move tonneau well liner arou nd lower cylinder fixing
and pump casing and secure velcro.
12. Install trim clip and positi on tonneau lining stiffening
rod.
13. Connect battery.
14. Restore roof and tonneau to original position
Hydraulic Cylinder Valve to Pump Pipe -
Renew
Removal
1. Operate roof to halfway position with tonneau open then support roof when hydr aulic pressure drops with
suitable straps and support tonneau cover with suitable
prop (see Figure 1).
2. Disconnect battery.
Figure 11
Figure 1
Repair Operation Time (ROT)

Convertible Roof (01.17)
Body System (01.00)1-12-66 Workshop Manual May 2007
14. Loosen (x6) screws on pump retaining plate (see Figure
10).
15. Slide retaining plate, discon nect pipe from pump (pipes
and locations are numbered).
16. Remove cable ties and remove pipe from vehicle (see Figure 11).
Installation
1. Check oil level and top-up if necessary by removing reservoir end plug with pump in upright position, add small quantity of oil replace plug and re-check level (see
Figure 1).
2. Install pipe to approximate route on vehicle and install
cable ties.
3. Clean pipe and install pipe to pump then slide retaining plate into place and tighten screws. (pipes and locations
are numbered).
4. Install motor casing and secure velcro.
5. Install motor and casing under tonneau onto location posts.
6. Install cylinder pivot bracket and connect cylinder to bracket.
7. Move tonneau well liner around lower cylinder fixing and motor casing and secure velcro
8. Position tonneau liner to body and install clips.
9. Install trim clip and position tonneau lining stiffening rod.
10. Clean pipe, connect pipe to valve, slide retaining plate
and tighten screw.
11. Install valve to support bracket, reposition bracket.
12. Install cable tie securing valve to bracket. Ensure no
pipes or wiring will foul roof mechanism.
13. Connect battery.
14. Restore roof and tonneau to original positionWind Deflector - Renew
Removal
1. Operate roof to halfway position with tonneau open then support roof when hydraulic pressure drops with
Figure 10
Figure 11
Figure 1
Repair Operation Time (ROT)
ItemCode
Wind Deflector-Renew 01.17.DA

Restraining Devices (01.20)
Body System (01.00)1-14-4 Workshop Manual May 2007
event that does not. The RCM governs the operation of the
whole system and performs continual system diagnostics.
Information on the severity of an impact is received from the
impact sensors.
Variations in the deployment of the front airbag modules are
dependent on the status of the front safety belt buckles.
Dual Inflation Technology
When activated, the airbags will deploy at either a normal or
reduced level of inflation, depending on crash severity.
Various sensors determine the direction and severity of an
impact. The system analyses this information then deploys
the appropriate airbags.
Impact Sensors
Side Impact - Side impact sensors are mounted to the base
of each B-pillar and within each door. In the event of a side
impact, the RCM processes the impact data sent by the side
impact sensor against stored data. The RCM will deploy the
side airbag on the side the deployment request was initiated
and the seat belt pretensioner.
Front Impact - Front impact sensors (x2) are located under
the grill opening panel.
The SRS module processes the impact data sent by the front
impact sensor against stored data, and deploys the front
airbags, and the seat belt pretensioners.
Passenger Airbag Deactivation
The passenger airbag can be deactivated using the PAD
(Passenger Airbag Deactivation) switch. Switching the
passenger airbag off allows children under the age of 12 to
be carried safely in the passenger seat. The PAD switch is
located at the passenger end of the instrument panel and is
accessible when the pa ssenger door is open.
Maintenance
Driver’s Airbag Module - Renew
Removal
1. Disconnect vehicle battery.
2. Allow a two minute power down period to de-activate
airbag system.
3. Rotate steering wheel to access and remove bolts (x2) from driver's airbag module to steering wheel (see
Figure 1).
4. Release driver's airbag mo dule, disconnect multiplugs
(x2) and remove airbag module (see Figure 2).
Installation
1. Position driver's airbag mo dule and connect multiplugs
(x2).
2. Install bolts (x2) and tighten.
3. Connect vehicle battery.
LH Front Seat Belt - Renew
Removal
1. Remove front seat (see Workshop Manual procedure 01.10.AB Seat Assembly - Front - LH - Remove for
Access and Refit).
Note
Please see the Owner’s Guid e for the full deactivation
procedure.
Warning
Unnecessary deactivation of the passenger airbag is
dangerous. The passenger will not receive the added
protection from the airbag and serious injuries or even
death could occur. With the exception of installing a child seat on the passenge r seat, do not turn the
passenger airbag deactiva tion switch to the off
position.
Warning
Never place a child in a child seat or on a booster
cushion in the passenger seat if the airbag is active.
Repair Operation Time (ROT)
Figure 1
Figure 2
Repair Operation Time (ROT)
ItemCode
Front Seat Belt-Renew LH01.20.BA

Restraining Devices (01.20)
Body System (01.00)1-14-6 Workshop Manual May 2007
5. Disconnect pre-tensioner mu ltiplug, release multiplug
from mounting bracket (see Figure 2).
6. Release harness fir tree clips (x2) from seat belt mounting bracket.
7. Release main fuse clips from seat belt mounting bracket.
8. Remove bolts (x4) securing seat belt mounting bracket to body.
9. Remove seat belt assembly.
10. Remove bolt securing seat belt stalk to seat frame, remove stalk.
Installation
1. Position seat belt stalk to seat frame, install and torque tighten bolt.
2. Install seat belt assembly, in stall and torque tighten bolts
(x4).
3. Install seat belt in upper anchor mounting plate.
4. Position seat belt upper anchor mounting plate, install and torque tighten bolts (x5).
5. Install main fuse to mounting bracket.
6. Secure harness fir tree clips (x2) in mounting bracket.
7. Connect pre-tensioner multip lug, secure multiplug in
mounting bracket.
8. Install moulding assembly - quartet trim upper - LH (see Workshop Manual procedure 01.05.CL Moulding
Assembly - Quarter Trim Upper - RH - Renew).
9. Install front seat (see Workshop Manual procedure 01.10.AA Seat Assembly - Front - RH - Remove for
Access and Refit).
Passenger Airbag - Renew
Removal
1. Disconnect vehicle battery for minimum of 2 minutes.
2. Remove airbag panel and door assembly (see Workshop Manual procedure 01.12.AJ Panel and Door Assembly -
Air Bag - Renew).
3. Remove bolts (x4) securing airbag unit.
4. Disconnect multiplugs (x2), remove airbag unit.
Installation
1. Install airbag unit, install and tighten bolts (x4), connect multiplugs (x2).
2. Install airbag panel and d oor assembly (see Workshop
Manual procedure 01.12.AJ Panel and Door Assembly -
Air Bag - Renew).
3. Connect vehicle battery.
ARS Side Impact Sensor Assembly - B
Pillar-Renew
Removal
1. Remove plate - front sill - RH (see Workshop Manual procedure 01.05.AJ Plate - Front Sill - RH - Renew).
2. Pull back sill carpet sufficient to access side impact sensor.
3. Disconnect multiplug from side impact sensor (see Figure 1).
4. Remove screws (x2) securing side impact sensor to inner
sill, remove sensor.
Installation
1. Install side impact sensor, install and tighten screws (x2).
2. Connect multiplug to side impact sensor.
3. Re-position sill carpet.
4. Install plate - front sill - RH (see Workshop Manual procedure 01.05.AJ Plate - Front Sill - RH - Renew).
Side Impact Door ARS Sensor Assembly -
Renew
Figure 2
A0120187
Repair Operation Time (ROT)
ItemCode
Passenger Airbag -Renew 01.20.CA
Repair Operation Time (ROT)
ItemCode
ARS Side Impact Sensor Assembly-B-
pillar-Renew 01.20.DB
Repair Operation Time (ROT)
ItemCode
Side Impact Door ARS Sensor Assembly-
Renew 01.20.DD

Subframes (02.03)
Frame and Mounting (02.00)
2-1-6 Workshop Manual May 2007
32. Position trolley, support subframe, remove bolts (x12)and raise vehicle.
Installation
1. Install subframe to body and remove trolley.
2. Install steering rack nuts (x3) and tighten.
3. Install engine mounting nuts (x2) and tighten.
4. Install harness clips (x2).
5. Install ride height sensor and tighten nut.
6. Install undertray (See Workshop Manual procedure 01.02.NB Undertray - Front - Renew).
7. Lower ramp.
8. Remove engine lifting beam.
9. Remove special tool SPX M553D.
10. Remove engine lifting bracket s from engine using special
tool 303-749.
11. Remove cross brace support bracket fixings (x6).
12. Install EGR valve and tighten.
13. Install front spring and damper assemblies (See Workshop Manual procedure 04.03.AA Spring and
Damper Assembly - Front Pair - Renew).
14. Install RH wheel arch liner (See Workshop Manual procedure 01.02.GB Wheel Arch Liner - Front - RH -
Renew).
15. Install LH wheel arch liner (See Workshop Manual procedure 01.02.FB Wheel Arch Liner - Front - LH -
Renew).
16. With assistance, install suspension assemblies, lower suspension arms, bolts and nuts (x4) and cam washers
(x2) (do not torque tighten at this stage).
17. Install upper suspension arms to body (do not torque tighten at this stage).
18. Install ride height sensor link to lower suspension arm and tighten.
19. Install and tighten nuts (x2) from track rod ends to vertical link.
20. Install anti-roll bar to links and tighten.
21. Clean and Install brake discs and tighten Torx screws (x4). 22. Install brake callipers and tighten Allen bolts (x4).
23. Connect brake pad wear se
nsor multiplug and secure
harness clips (x4) in upper suspension arms.
24. Connect ABS sensor multiplu gs and secure harness clips
(x6) in upper suspension arms and vertical links.
25. Install road wheel/s.
26. Lower vehicle on ramp.
27. Switch battery isolation switch ‘ON’.
28. 4 wheel alignment check and adjust (See Workshop Manual procedure 04.00.AD 4 Wheel Alignment -
Check and Adjust).
Rear Subframe-Renew
Removal
1. Battery isolation switch ‘OFF’.
2. Raise vehicle on ramp and make safe.
3. Remove road wheel(s).
4. Remove LH rear wheel arch liner (see Workshop Manual procedure 01.02.JB Wheel Arch Liner - Rear -
LH - Renew).
5. Remove RH rear wheel arch liner (see Workshop Manual procedure 01.02.HB Wheel Arch Liner - Rear -
RH - Renew).
6. Remove rear muffler asse mbly (see Workshop Manual
procedure 09.00.KA Silencer and Bypass Valve
Assembly - Remove for Access and Refit).
7. Remove bolts (x4), rear subframe cross brace.
8. Loosen clamps (x2), LH and RH rear exhaust pipes from
centre pipe.
9. Remove rear exhaust pipes through subframe.
10. Loosen clamps (x2), centre exhaust pipe to LH and RH
catalysts.
11. Release centre exhaust pipe from mountings, LH and RH catalysts, remove centre pipe.
12. Remove bolts (x4), centre heatshield.
13. Remove bolts (x8), shear plate to body.
14. Remove bolt securing earth lead to transaxle.
Fig. 6
Repair Operation Time (ROT)
ItemCode
Rear Subframe-Renew 02.01.CA
Caution
When using a 'two post' vehicle ramp, remove the
screws that secure the rear section of the wheel arch
liner to body. Hold back the rear section of the wheel
arch liner to correctly position the foot of the vehicle lift.
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.
Warning
To avoid personal injury, i.e. severe burns to the skin, allow exhaust system to cool down before removing
exhaust system components.

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

Subframes (02.03)
Frame and Mounting (02.00)
2-1-8 Workshop Manual May 2007
8. Remove bolts (x2), remove both spring/damper assemblies.
9. Remove nuts (x2), anti-roll bar links to lower suspension
arms.
10. Remove bolts (x4). anti-roll bar to subframe. Remove anti-roll bar.
11. Disconnect ABS sensor mult iplugs (x2), release sensor
harness clips (x4) from both toe control arms.
12. Disconnect brake pad wear sensor multiplugs (x2). Release connectors (x2) from subframe.
13. Loosen and disconnect brake pipe unions (x2) from subframe brackets. Pl ug pipe connections.
14. Disconnect multiplug fr om ride height sensor.
15. Remove nut/bolt securing ride height sensor link to
upper suspension arm.
16. Remove bolts (x2), ride height sensor to subframe. Remove sensor.
17. Remove nuts/bolts (x2) and cam washers (x2), toe control arms to subframe.
18. Remove bolts (x2), nuts/bolts (x2) and cam washers (x2),
securing lower suspension arms to subframe
19. Remove nuts/bolts (x4), upper suspension arms to subframe.
20. With assistance, remove suspension assemblies from subframe.
21. Remove heatshield clips (x2) from rear of subframe.
22. Release clips (x23), ha rness to subframe, remove
harness.
23. Release brake pipes from cl ips (x7), remove pipes (x2).
24. Remove brake pipe clips (x5) from subframe.
Installation
1. Clean suspension components and brake pipes.
2. Instal brake pipe clips (x5) in subframe.
3. Install brake pipes (x2) in clips (x7).
4. Install harness and secure with clips (x23).
5. Install heatshield clips (x2).
6. With assistance, install suspension assemblies in subframe.
7. Install bolts/nuts (x4), upper suspension arm to subframe. Do not torque tighten at this stage.
8. Install bolts (x2), bolts/nuts (x2) and cam washers (x2) securing lower suspension arm to subframe. Do not
torque tighten at this stage.
9. Position toe control arm, install bolts (x2, cam washers (x2 and nuts (x2). Do not torque tighten at this stage.
10. Install ride height sensor, in stall and torque tighten bolts
(x2).
11. Align ride height sensor li nk to upper suspension arm,
install bolt/nut, tighten to correct torque.
12. Connect multiplug to ride height sensor. 13. Remove pipe plugs, install and torque tighten brake
pipe unions.
14. Connect brake pad wear sensor multiplugs, install in subframe brackets.
15. Connect ABS sensor multiplugs (x2), install harness clips (x4), in toe control arms.
16. Install anti-roll bar, install bolts (x4). Do not torque tighten at this stage.
17. Align anti-roll bar links to lower suspension arms. Install nuts (x2), do not torque tighten at this stage.
18. Install spring/damper assemblies (x2). Install bolts (x2), do not torque tighten at this stage
19. With assistance, install transaxle in subframe. Install and torque tighten hydramount nuts (x2).
20. Lower hoist, remove slings.
21. Align driveshafts to transaxle flanges, install plates (x6), new Allen bolts (x12) and tighten to correct torque.
22. Install rear subframe asse mbly (see Workshop Manual
procedure 02.01.CA Subframe Assembly - Rear -
Remove for Access and Refit).
23. Connect vehicle battery.
24. 4 wheel alignment check/adjust (see Workshop Manual procedure 04.00.AD 4 Wheel Alignment - Check and
Adjust).
25. Final torque tighten all suspension nuts/bolts.
RH/LH Transmission Rear Hydromount
Isolator Assembly-Renew
Removal
1. Raise vehicle on ramp.
2. Remove rear exhaust silenc er (see Workshop Manual
procedure 09.00.KA Silencer and Bypass Valve
Assembly - Remove for Access and Refit).
3. Remove bolts (x4) from subframe cross brace.
4. Loosen clamp nut and release rear exhaust pipe from centre pipe.
5. Remove rear exhaust pipe through subframe.
6. Position hydraulic lift er to support transaxle.
Caution
Always plug pipe connections to prevent ingress of dirt.
New Allen bolts should have a thread lock coating.
Caution
Final tightening of suspension components must be
carried out with the suspensi on arms at normal ride
height.
Repair Operation Time (ROT)
ItemCode
Transmission Rear Hydromount
Isolator Assembly-Renew RH
02.03.BC
Transmission Rear Hydromount
Isolator Assembly-Renew LH
02.03.BD
Warning
To avoid personal injury, i.e. severe burns to the skin, allow exhaust system to cool down before removing
exhaust system components.

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

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

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