BATTERY SYSTEM ASTON MARTIN V8 VANTAGE 2010 Repair Manual

Engine Structure (03.01)
3-1-8Workshop ManualIssue 4, November 2008
23. Install fuel feed pipe.
24. Install purge pipe P-clip.
25. Install harness bracket to engine.
26. Refit harness fir tree clips to cylinder head.
27. Refit engine breather hose.
28. Install VVT solenoid multiplug, position coil and CMP
harness (1x edge clip).
29. Install corner cross brace (torque bolts with vehicle on level ground).
30. Install coil cover.
Installation LH Side
31. Connect breather hose to manifold (quickfit).
32. Connect IAT multiplug.
33. Install injector harness to cam cover (x2).
34. Connect injector multiplugs (x4).
35. Install pipe support bracket (nuts x2, bolts x2).
36. Install harness support bracket (bolt x1, nut x2) release harness clips (fir tree x3).
37. Connect booster hose to manifold and support clip.
38. Connect heater hose from pipe (quick fit).
39. Install heater hose (x2) and throttle body hose (x2) from
support bracket.
40. Connect purge line to manifold and into support clip.
41. Connect breather hoses (x2) to cam cover.
42. Feed harness into inner wing area.
43. Install fusebox to bracket.
44. Install earth lead to fusebox.
45. Install battery lead to fusebox (1x nut and rubber cover).
46. Install multiplugs to fuse box.
47. Install fusebox bracket fixings.
48. Install ECM (see Workshop Manual procedure 03.13.ND Module - Power Train Control - RHD -
Renew).
49. Install coil cover.
50. Refill coolant (see Workshop Manual procedure 03.03.AD Coolant - Drain and Refill).
51. Install cross brace. (torque bolts with vehicle on level
ground).
Upper Intake Manifold Assembly Gasket
(LHD) - Renew
Removal
1. Depressurise fuel rail (see Workshop Manual procedure 10.01.EK Fuel System - Depressurise).
2. Coolant drain (see Workshop Manual procedure 03.03.AD Coolant - Drain and Refill). 3. Remove cross brace (bolts x4).
Removal R/H Side
4. Remove coil cover.
5. Disconnect breather hose (quick fit) move aside.
6. Release (alt/inj) harness fir tr
ee clips (x3) from cylinder
head and move aside.
7. Remove fuse box bracket fixings (bolt and nut) (allows movement).
8. Remove ECM (see Workshop Manual procedure 03.13.NC Module - Powe r Train Control - Renew).
9. Remove battery lead (x1nut and rubber cover) from fuse box (2x leads).
10. Remove multiplugs (x10) from fusebox.
11. Remove earth terminal (1x nut and rubber cover) from fusebox.
12. Remove fuse box from bracket (bolt x2).
13. Release harness fir tree clips (x3) from engine bracket.
14. Feed harness from inner wing and over engine to gain access to cam cover.
15. Remove purge pipe P-clip (bolt x1) and move pipe
aside.
16. Remove harness bracket from engine (bolts x2, nut x1).
17. Release fuel feed hose from rail (clip x1) and move aside.
18. Disconnect heater hose from pipe (quick fit).
19. Release heater hose (clips x2) and EGR vacuum line (clips x2) from bracket.
20. Release (inj/alt) harness from coolant pipe bracket (fir tree x3).
21. Disconnect EGR (x1), fuel rail pressure sensor (x1) and injector multiplugs (x4), move harness aside.
22. Remove coolant pipe bracke t (nuts x2 and bolts x2).
23. Disconnect EGR vacuum pipe from sensor and
manifold, move aside.
Removal L/H Side
24. Remove corner cross brace.
25. Remove coil cover.
26. Disconnect breather hoses from cam cover (x2) for access.
27. Disconnect purge line from manifold (quickfit) and
support clip for access.
28. Disconnect heater hose from pipe (quick fit).
29. Release heater hose (x2) and throttle body hose (x2) from support bracket.
30. Remove booster hose from manifold and support clip.
31. Remove harness support bracket (bolt x1, nut x2) release harness clips (fir tree x3).
32. Release pipe support bracket (nuts x2, bolts x2) move aside.
33. Disconnect injector multiplugs (x4).
34. Unclip injector harness from cam cover (x2).
35. Disconnect IAT multiplug.
36. Disconnect breather hose from manifold (quickfit).
Repair Operation Time (ROT)

Engine Structure (03.01)
Issue 4, November 2008Workshop Manual 3-1-9
Removal Manifold
37. Disconnect manifold heating hoses (x2).
38. Disconnect throttle body multiplug and harness clip.
39. Disconnect breather pipe qu ickfits (x2) from air cleaner
duct.
40. Disconnect air clea ner duct (clip x1).
41. Disconnect EGR vacuum hose.
42. Disconnect EGR pipe union and tie aside.
43. Remove manifold bolts (x 10) (see Figure 1).
Figure 1
44. Remove bolts (x2) bracket to manifold (rear).
45. Move manifold (2x people) forward, remove bolt for purge line P-clip, remove manifold.
46. Remove gaskets and clean mating faces.
Installation
Manifold to Vehicle
1. Install new gaskets to cylinder block (glue in place).
2. Install manifold (allowing access to install bolt for purge line P-clip).
3. Install manifold bolts (x10) (torque and tightening sequence).
4. Install bolts (x2) bracket to manifold (rear).
5. Connect EGR pipe union.
6. Connect EGR vacuum hose.
7. Connect air cleaner duct (clip x1).
8. Connect breather pipe quickf its (x2) to air cleaner duct.
9. Connect throttle body multiplug and harness clip.
10. Connect manifold heating hoses (x2).
Installation RH Side
11. Connect EGR vacuum pipe to sensor and manifold.
12. Install coolant pipe bracket (bolt x2, nut x2).
13. Connect EGR (x1), fuel rail pressure sensor (x1) and
injector multiplugs (x4).
14. Refit (inj/alt) harness to coolant pipe bracket (fir tree x3).
15. Connect heater hose to pipe (quick fit).
16. Refit heater hose (clipx2) and EGR vacuum lines (clips x2) to bracket.
17. Install fuel feed pipe.
18. Install purge pipe P-clip.
19. Install harness bracket to engine. 20. Feed harness into inner wing area.
21. Install fusebox to bracket.
22. Install earth lead to fusebox.
23. Install battery lead to fusebox (1x nut and rubber cover).
24. Install multiplugs to fuse box.
25. Install fusebox bracket fixings.
26. Refit harness fir tree clips to cylinder head.
27. Refit engine breather hose.
28. Install VVT solenoid multip
lug, position coil and CMP
harness (1x edge clip).
29. Install ECM (see Workshop Manual procedure 03.13.NC Module - Power Train Control - Renew).
30. Install coil cover.
Installation LH Side
31. Connect breather hose to manifold (quickfit).
32. Connect IAT multiplug.
33. Unclip injector harness from cam cover (x2).
34. Connect injector multiplugs (x4).
35. Install pipe support bracket (nuts x2, bolts x2).
36. Install harness support bracket (bolt x1, nut x2) release harness clips (fir tree x3).
37. Connect booster hose to manifold and support clip.
38. Connect heater hose from pipe (quick fit).
39. Install heater hose (x2) and throttle body hose (x2) from support bracket.
40. Connect purge line to manifold and into support clip.
41. Connect breather hoses (x2) to cam cover.
42. Install coil cover.
43. Install corner cross brace (t orque bolts with vehicle on
level ground).
44. Refill coolant (see Workshop Manual procedure 03.03.AD Coolant - Drain and Refill).
45. Install cross brace. (torque bolts with vehicle on level
ground).
Upper Intake Manifold Assembly Gasket
(RHD) - Renew
Removal
1. Depressurise fuel rail (see Workshop Manual procedure 10.01.EK Fuel System - Depressurise).
2. Coolant drain (see Workshop Manual procedure 03.03.AD Coolant - Drain and Refill).
3. Remove cross brace (bolts x4).
Removal RH Side
4. Remove coil cover.
5. Remove corner cross brace.
A030113
Note: The installation is not handed
Repair Operation Time (ROT)

Cooling System (03.03)
Engine (03.00)
Issue 5, Janauary 2010 Workshop Manual 3-3-3
13. Install and tighten pressure cap.
14. Run engine until normal operating temperature is reached.
15. Stop engine, allow to cool down.
16. Re-check coolant level, top-up as necessary.
Thermostat - Renew
Removal
1. Drain Coolant (refer to Workshop Manual procedure 03.03.AD Coolant - Drain and Refill).
2. Release breather valve (bolt x1) and tie aside.
3. Unclip engine harness for access (x4).
4. Remove one end of engine breather hoses for access (x3).
5. Remove breather valve bracket for access (nuts x2 bolt x1).
6. Remove thermostat housing from manifold (bolt x3).
7. Remove thermostat and sealing ring.
Installation
1. Install new thermostat and sealing ring .
2. Install thermostat housing (torque).
3. Install breather valve bracket.
4. Install breather hoses (x3) and clip.
5. Clip engine harness.
6. Install breather valve.
7. Refill coolant (refer to Workshop Manual procedure 03.03.AD Coolant - Drain and Refill).
Wa t e r P u m p - R e n e w
Removal
1. Drain cooling system (refer to Workshop Manual procedure 03.03.AD Coolant - Drain and Refill).
2. Disconnect breather pipe qu ickfits (x2) from air cleaner
duct.
3. Remove throttle body du ct for access. (clips x3). 4. Remove pump pulley bolts (x
3) (refer to Figure 1).
Figure 1
5. Release tensioner and slip belt from idler.
6. Remove pump pulley.
7. Remove pump (bolts x7 ) (refer to Figure 2).
Figure 2
Installation
1. Install pump (bolts x7) (torque), clean mating faces.
2. Fit pulley to pump with bolts.
3. Torque pulley bolts (bolt x3).
4. Release tensioner and slip belt on idler.
5. Install throttle body duct.
6. Connect breather pipe quickf its (x2) to air cleaner duct.
7. Refill cooling system (refer to Workshop Manual procedure 03.03.AD Coolant - Drain and Refill).
Water Pump Pulley - Renew
Removal
1. Battery isolation switch ‘OFF’.
2. Disconnect breather pipe qu ickfits (x2) from air cleaner
duct.
WA R N I N G
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.
Repair Operation Time (ROT)
Repair Operation Time (ROT)
Repair Operation Time (ROT)
A030350
A030351

Cooling System (03.03)
Engine (03.00)3-3-4 Workshop Manual Issue 5, Janauary 2010
3. Remove throttle body duct for access. (clips x3).
4. Remove pump pulley bolts (x 3) (refer to Figure 1).
Figure 1
5. Release tensioner and slip belt from idler.
6. Remove pump pulley.
Installation
1. Fit pulley to pump with bolts.
2. Torque pulley bolts (bolt x3).
3. Release tensioner and slip belt on idler.
4. Install throttle body duct.
5. Connect breather pipe quickf its (x2) to air cleaner duct.
6. Battery isolation switch ‘ON’.
Oil Temperature Controller - Renew
Remove
1. Raise vehicle on ramp.
2. Remove undertray (refer to Workshop Manual procedure 01.02.NB Undertray - Front - Renew). 3. Remove pipes from oil thermostat (position container to
catch oil) (refer to Figure 1).
Figure 1
4. Remove controller fr om body (bolts x2).
Install
1. Install controller to body (bolts x2) (torque).
2. Install pipes to oil thermost at (torque) ensure correct
alignment in oil tank bracket.
3. Install undertray (refer to Workshop Manual procedure 01.02.NB Undertray - Front - Renew).
4. Fill tank with approximatel y amount of displaced oil and
replace cap.
5. Use handbook procedure to check oil level.
6. Lower vehicle on ramp.
Radiator Fan and Motor Assembly -
Remove and Install
Removal
1. Open the boot..
2. Set the battery isolation switch to off.
3. Remove the radiator closing panel. (01.02.AA - Radiator Closing Panel).
4. Disconnect the two electrical connectors from the wiring harness for the radiator fan and motor assembly.
5. Remove the two bolts that attach the horn mount bracket to the body.
6. Move the horn assembly away.
7. Remove the two nuts that attach the radiator fan and motor assembly to the body.
8. Remove the radiator fan and motor assembly.
Installation
1. Install the radiator fan and motor assembly.
2. Install and tighten the two nuts that attach the radiator fan and motor assembly to the body.
Repair Operation Time (ROT)
A030350
Repair Operation Time (ROT)
ItemCode
Radiator Fan and Motor Assembly -
Remove and Install 03.03.DB
A030242

Cooling System (03.03)
Engine (03.00)
Issue 5, Janauary 2010 Workshop Manual 3-3-5
3. Put the horn assembly into the correct position.
4. Install and tighten the two bolts that attach the horn mount bracket to the body.
5. Connect the two electrical connectors to the wiring harness for the radiator fan and motor assembly.
6. Install the radiator closin g panel. (0102AA - Radiator
Closing Panel).
7. Set the battery isolation switch to on.
8. Close the boot.
Radiator and Condenser Assembly -
Renew
Removal
1. Remove cooling fan pack (refer to Workshop Manual procedure 03.03.DB Fan and Motor Assembly -
Radiator - Renew).
2. Remove grille (refer to Workshop Manual procedure 01.08.AA Grille - Radiator - Renew).
3. Drain cooling system (refer to Workshop Manual procedure 03.03.AD Coolant - Drain and Refill).
4. Recover refrigerant (refer to Workshop Manual procedure 12.03.FA Refrigerant Gas - Recover/Recharge
- Renew).
5. Remove bolts (x4), that attach the PAS fluid cooler to bonnet latch cross member. Tie fluid cooler aside.
6. Remove bolts (x6), and spacers (x2) that attach the bonnet latch cross member to body and position aside.
7. Disconnect top and bottom hose from radiator (clips
x2).
8. Remove expansion tank hose from radiator (clip x1).
9. Remove bolts (x2), that attach the condenser pipe connections. Plug pipes and block connections.
10. Remove radiator mounting rubbers (x4)
11. Remove foam seals from radiator (x3).
Installation
1. Install foam seals to radiator (x3).
2. Install rubber mounts to radiator (x4).
3. Clean pipe connections, remove plugs.
4. Install new 'O' rings to pipe connections. Connect pipes to condenser. Install and torque tighten bolts (x2).
5. Connect top and bottom hoses to radiator (clips x2).
6. Connect expansion tank hose to radiator (clip x1). 7. Install bonnet latch cross member, install spacers and
bolts (torque).
8. Position PAS fluid cooler to cross member, install and
torque tighten bolts (x4).
9. Install grill (refer to Workshop Manual procedure
01.08.AA Grille - Radiator - Renew).
10. Install cooling fan pack (refer to Workshop Manual procedure 03.03.DB Fan and Motor Assembly -
Radiator - Renew).
11. Recharge refrigerant (refer to Workshop Manual procedure 12.03.FA Refriger ant Gas - Recover/Recharge
- Renew).
12. Refill cooling system (r efer to Workshop Manual
procedure 03.03.AD Coolant - Drain and Refill).
Radiator Assembly - Renew
Removal
1. Remove cooling fan pack (refer to Workshop Manual procedure 03.03.EB Fan and Motor Assembly Radiator -
Renew
2. Remove grille (refer to Workshop Manual procedure 01.08.AA Grille - Radiator - Renew).
3. Drain coolant (refer to Workshop Manual procedure 03.03.AD Coolant - Drain and Refill).
4. Remove bolt that attaches the PAS pipe bracket to bottom cross member.
5. Remove bolts (x6), and spacers (x2) that attach the bonnet latch cross member to body and position aside.
6. Disconnect top and bottom hose from radiator (clips x2).
7. Disconnect top and bottom hose from radiator (clips x2).
8. Remove expansion tank hos e from radiator (clip x1).
9. Remove bolts (x2) that attach the radiator to condenser.
10. Unclip condenser from ra diator and remove from
vehicle (lugs x4) (support condenser).
11. Remove radiator mounting rubbers (x4)
1. Remove foam seals from radiator (x3).
Installation
1. Install foam seals to radiator (x3).
2. Install rubber mounts to radiator (x4).
3. Install radiator and clip to condenser (lugs x4).
4. Install condenser to radiator bolts x2 (torque).
5. Connect top and bottom hoses to radiator (clips x2).
6. Connect expansion tank hose to radiator (clip x1).
7. Install bonnet latch cross member, install spacers and bolts (torque).
8. Position PAS fluid cooler to cross member, install and
torque tighten bolts (x4).
Repair Operation Time (ROT)
Repair Operation Time (ROT)

Fuel Charging System (03.04)
Engine (03.00)
May 2007 Workshop Manual 3-4-1
Engine (03.00)
Fuel Charging System (03.04)
Safety Precautions
Operations on fuel system result in fuel liquid and vapour
being present in the working environment. This presents a
very serious risk and the following precautions must be
strictly observed:
WAR NI NG
OPERATIONS ON REFUELLING AND THE FUEL
SYSTEM MUST ONLY BE PERFORMED BY PERSONNEL WHO HAVE COMPLETED TRAINING ON FUEL HANDLING.
WAR NI NG
SMOKING MUST NOT BE ALLOWED NEAR THE
WORKING AREA. “NO SMOKING” SIGNS MUST BE POSTED AROUND THE WORKING AREA.
WAR NI NG
ANY OPERATION WHICH COULD INVOLVE SPARKS OR NAKED LIGHTS (E.G. BATTERY TESTING,
WELDING, METAL GRINDING, ETC.) MUST NOT BE ALLOWED NEAR THE WORKING AREA.
WAR NI NG
A CO2 FIRE EXTINGUISHER MUST BE AVAILABLE CLOSE AT HAND.
WAR NI NG
DRY SAND MUST BE AVAILABLE CLOSE AT HAND TO SOAK UP ANY ACCIDENTAL FUEL SPILLAGE.
WAR NI NG
IF NECESSARY, EMPTY THE FUEL INTO AN
EXPLOSION PROOF CONTAINER USING SUITABLE
FIREPROOF FUEL HANDLING EQUIPMENT.
WAR NI NG
THE WORKING AREA MUST BE WELL VENTILATED.
WAR NI NG
DISCONNECT THE BATTERY BEFORE COMMENCING WORK ON THE FUEL SYSTEM.
WAR NI NG
DEPRESSURISE THE FUEL SYSTEM BEFORE DISCONNECTING ANY FUEL LINES.

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

Fuel Charging System (03.04)
Engine (03.00)
May 2007 Workshop Manual 3-4-3
Installation Manifold to Vehicle
3. Install new gaskets to cylinder block (glue in place).
4. Install manifold (allowing access to install bolt for purge
line P-clip).
5. Install manifold bolts (x10) (torque and tightening sequence).
6. Install bolts (x2) bracket to manifold (rear).
7. Connect EGR pipe union.
8. Connect EGR vacuum hose.
9. Connect air cleaner duct (clip x1).
10. Connect breather pipe quickf its (x2) to air cleaner duct.
11. Connect throttle body multiplug and harness clip.
12. Connect manifold heating hoses (x2).
Installation RH Side
13. Connect EGR vac pipe to sensor and manifold.
14. Install coolant pipe bracket (bolt x2, nut x2).
15. Connect EGR (x1), fuel rail pressure sensor (x1) and
injector multiplugs (x4).
16. Refit harness to coolant pipe bracket (fir tree x3).
17. Connect heater hose to pipe (quick fit).
18. Refit heater hose (clipx2) and EGR vacuum lines (clips x2) to bracket.
19. Install fuel feed pipe.
20. Install purge pipe P-clip.
21. Install harness bracket to engine.
22. Feed harness into inner wing area.
23. Install fusebox to bracket.
24. Install earth lead to fusebox.
25. Install battery lead to fusebox (1x nut and rubber cover).
26. Install multiplugs to fuse box.
27. Install fusebox bracket fixings.
28. Refit harness fir tree clips to cylinder head.
29. Refit engine breather hose.
30. Install VVT solenoid multip lug, position coil and CMP
harness (1x edge clip).
31. Install ECM (see Workshop Manual procedure 03.14.BB XREF: 319 Engine Control Module - RH Renew
32. Install coil cover.
Installation LH Side
33. Connect breather hose to manifold (quickfit).
34. Connect IAT multiplug.
35. Unclip injector harness from cam cover (x2).
36. Connect injector multiplugs (x4).
37. Install pipe support bracket (nuts x2, bolts x2).
38. Install harness support bracket (bolt x1, nut x2) release harness clips (fir tree x3).
39. Connect booster hose to manifold and support clip. 40. Connect heater hose from pipe (quick fit).
41. Install heater hose (x2) and throttle body hose (x2) from
support bracket.
42. Connect purge line to manifold and into support clip.
43. Connect breather hoses (x2) to cam cover.
44. Install coil cover.
45. Install corner cross brace (t orque bolts with vehicle on
level ground).
46. Refill coolant (see Workshop Manual procedure 03.03.AD Coolant - Drain and Refill).
47. Install cross brace (torque bolts with vehicle on level
ground).
Fuel Injection Pressure Sensor - Renew
Removal
1. Depressurise fuel rail (see Workshop Manual procedure 10.01.EK Fuel System - Depressurise).
2. Disconnect vacuum hose.
3. Remove sensor from fuel rail (bolts x2).
4. Disconnect multiplug.
Installation
1. Install sensor to fuel rail (bolts x2) (torque).
2. Connect multiplug.
3. Connect vacuum hose.
Fuel Temperature Sensor - Renew
Removal
1. Depressurise fuel rail (see Workshop Manual procedure 10.01.EK Fuel System - Depressurise).
2. Disconnect vacuum hose.
3. Remove sensor from fuel rail (bolts x2).
4. Disconnect multiplug.
Installation
1. Install sensor to fuel rail (bolts x2) (torque).
2. Connect multiplug.
3. Connect vacuum hose.
WA R N I N G
THE INTAKE MANIFOLD IS HEAVY. TO AVOID
PERSONAL INJURY OR DAMAGE TO THE INTAKE MANIFOLD, INTAKE MANIFOLD REMOVAL /
ISTALLATION IS A TWO PERSON OPERATION.
Installation Not Handed
Repair Operation Time (ROT)
Repair Operation Time (ROT)

Fuel Charging System (03.04)
Engine (03.00)3-4-4 Workshop Manual May 2007
Fuel Injector Engine Set - Renew
Removal
1. Remove LH injectors (see Workshop Manual procedure
03.04.GH Injector - Fuel - LH Bank - Engine Set -
Renew).
2. Remove coils (see Work shop Manual procedure
03.07.HC Coil Assembly - Engine Set - RH - Renew).
3. Disconnect breather hose (quick fit) move aside.
4. Release harness fir tree clips (x3) from cylinder head and move aside.
5. Remove fuse box bracket fixings (bolt and nut) (allows movement).
6. Remove ECM (see Workshop Manual procedure 03.14.BB Engine Control Module - RH Renew).
7. Remove battery lead (1x nu t and rubber cover) from
fuse box (2x leads).
8. Remove multiplugs (x10) from fusebox.
9. Remove earth terminal (1x nut and rubber cover) from
fusebox.
10. Remove fuse box from bracket (bolt x2).
11. Release harness fir tree clips (x3) from engine bracket.
12. Feed harness from inner wing and over engine to gain access to cam cover.
13. Remove purge pipe P-clip (bolt x1) and move pipe
aside.
14. Remove harness bracket from engine (bolts x2, nut x1).
15. Release fuel feed hose from rail (clip x1) and move aside.
16. Disconnect heater hose from pipe (quick fit).
17. Release heater hose (clips x2) and EGR vacuum line (clips x2) from bracket.
18. Release harness from coolant pipe bracket (fir tree x3).
19. Disconnect EGR (x1), fuel rail pressure sensor (x1) and injector multiplugs (x4), move harness aside.
20. Remove coolant pipe bracket (nuts x2 and bolts x2).
21. Disconnect EGR vac pipe from sensor and manifold, move aside. 22. Remove Injector to rail clips (see Figure 1).
Figure 1
23. Remove fuel rail bolts (x2) and lift rail (tie aside) (see
Figure 2).
Figure 2
24. Remove injectors from manifold.
Installation
1. Install clips on to new injectors then fit injectors into manifold.
2. Install rail onto injectors (taking care each injector is aligned correctly and the clip seats properly) and fit bolts
(x2) (torque).
3. Connect EGR vac pipe to sensor and manifold.
4. Install coolant pipe bracket (bolt x2, nut x2).
5. Connect EGR (x1), fuel rail pressure sensor (x1) and
injector multiplugs (x4).
6. Refit harness to coolant pipe bracket (fir tree x3).
7. Connect heater hose to pipe (quick fit).
8. Refit heater hose (clipx2) and EGR vac lines (clips x2) to bracket.
9. Install fuel feed pipe.
10. Install purge pipe P-clip.
11. Install harness bracket to engine.
12. Feed harness into inner wing area.
13. Install fusebox to bracket.
14. Install earth lead to fusebox.
15. Install battery lead to fusebox (1x nut and rubber cover).
16. Install multiplugs to fuse box.
Repair Operation Time (ROT)
A030452
A030113A

Fuel Charging System (03.04)
Engine (03.00)
May 2007 Workshop Manual 3-4-5
17. Install fusebox bracket fixings.
18. Refit harness fir tree clips to cylinder head.
19. Refit engine breather hose.
20. Install VVT solenoid multiplug, position coil and CMP
harness (1x edge clip).
21. Install LH injectors (see Workshop Manual procedure
03.04.GH Injector - Fuel - LH Bank - Each - Renew).
22. Install ECM (see Workshop Manual procedure 03.14.BB Engine Control Module - RH Renew).
1. Install coils (see Workshop Manual procedure 03.07.HC
Coil Assembly - Engine Set - RH - Renew).
Fuel Injector - Each - LH Bank - Renew
Removal
1. Depressurise fuel rail (see Workshop Manual procedure 10.01.EK Fuel System - Depressurise).
2. Remove corner cross brace.
3. Disconnect breather hoses from cam cover (x2) for access.
4. Disconnect purge line from manifold (quickfit) and support clip for access.
5. Disconnect heater hose from pipe (quick fit).
6. Release heater hose (x2) and throttle body hose (x2) from support bracket.
7. Remove booster hose from manifold and support clip.
8. Remove harness support bracket (bolt x1, nut x2) release harness clips (fir tree x3).
9. Release pipe support bracket (nuts x2, bolts x2) move aside.
10. Disconnect IAT multiplug.
11. Disconnect injector multiplugs (x4).
12. Unclip injector harness from cam cover (x2).
13. Disconnect breather hose from manifold (quickfit).
14. Remove Injector to rail clip (for injector to be changed).
15. Remove fuel rail bolts (x2) and lift rail with remaining injectors (tie aside).
16. Remove injector from manifold.
Installation
1. Install new O-rings to remaining injectors (lube O-rings).
2. Install clip to new injector then injector into rail.
3. Install rail (with injectors) to manifold (bolt x2) (torque) (taking care each injector is aligned correctly).
4. Connect breather hose to manifold (quickfit).
5. Connect IAT multiplug.
6. Unclip injector harness from cam cover (x2).
7. Connect injector multiplugs (x4).
8. Install pipe support br acket (nuts x2, bolts x2). 9. Install harness support bracket (bolt x1, nut x2) release
harness clips (fir tree x3).
10. Connect booster hose to manifold and support clip.
11. Connect heater hose from pipe (quick fit).
12. Install heater hose (x2) and throttle body hose (x2) from support bracket.
13. Connect purge line to manifold and into support clip.
14. Connect breather hoses (x2) to cam cover.
15. Install corner cross brace (t orque bolts with vehicle on
level ground).
Fuel Injector - Each - RH Bank - Renew
Removal
1. Depressurise fuel rail (see Workshop Manual procedure 10.01.EK Fuel System - Depressurise).
2. Disconnect breather hose (quick fit) move aside.
3. Release harness fir tree clips (x3) from cylinder head and move aside.
4. Remove fuse box bracket fi xings (bolt and nut) (allows
movement).
5. Remove ECM (see Workshop Manual procedure 03.14.BB Engine Control Module - RH Renew).
6. Remove battery lead (1x nut and rubber cover) from fuse box (2x leads).
7. Remove multiplugs (x10) from fusebox.
8. Remove earth terminal (1x nut and rubber cover) from fusebox.
9. Remove fuse box from bracket (bolt x2).
10. Release harness fir tree clips (x3) from engine bracket.
11. Feed harness from inner wing and over engine to gain access to cam cover.
12. Remove purge pipe P-clip (bolt x1) and move pipe aside.
13. Remove harness bracket from engine (bolts x2, nut x1).
14. Release fuel feed hose from rail (clip x1) and move aside.
15. Disconnect heater hose from pipe (quick fit).
16. Release heater hose (clips x2) and EGR vacuum line
(clips x2) from bracket.
17. Release harness from coolan t pipe bracket (fir tree x3).
18. Disconnect EGR (x1), fuel rail pressure sensor (x1) and injector multiplugs (x4), move harness aside.
19. Remove coolant pipe bracket (nuts x2 and bolts x2).
20. Disconnect EGR vac pipe from sensor and manifold, move aside.
21. Remove Injector to rail clip (for injector to be changed).
22. Remove fuel rail bolts (x2) and lift rail with remaining injectors (tie aside).
23. Remove injector from manifold.
Repair Operation Time (ROT)
Repair Operation Time (ROT)