wheel torque ASTON MARTIN V8 VANTAGE 2010 Manual PDF
[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 551 of 947
Manual Transmission (07.03)
Transmission (07.00)
Issue 5, January 2010 Workshop Manual 7-3-35
8. Remove reverse light switch from transaxle (see Fig, 3).
9. Remove bolts (x3) from selector cable bracket to transaxle and collect bracket (see Figure 4).
10. Remove nuts (x2) from select or levers (x2) to transaxle
(see Figure 5).
Install
1. Clean reverse light switch, oil cooler pipes, selector levers and selector cable bracket. 2. Install selector levers (x2) and install and torque tighten
nuts (x2).
3. Install selector cable bracket and install and torque tighten bolts (x3).
4. Install and torque tighten reverse light switch.
5. Install oil cooler pipe assembly.
6. Install and torque tighten oil cooler pipe unions and support bracket bolt.
7. Fill transaxle with the specified oil to the correct level.
8. Attach slings to transaxle and connect hoist.
9. With assistance, remove transaxle from workbench and position on lifter.
10. Install transaxle assembly (see Workshop Manual procedure 07.03.AA Transaxle Assembly - Manual -
Remove for Access & Refit).
11. Install road wheel(s).
12. Test drive vehicle.
13. Raise vehicle on ramp and check transaxle oil level.
14. Lower vehicle on ramp.
Figure 3
Figure 4
Figure 5
WA R N I N G
THE TRANSAXLE ASSEMBLY IS VERY HEAVY. TO AVOID PERSONAL INJURY OR DAMAGE TO THE TRANSAXLE, HANDLING OF THE TRANSAXLE ASSEMBLY IS A TWO
PERSON OPERATION.
WA R N I N G
THE TRANSAXLE ASSEMBLY IS VERY HEAVY. TO AVOID PERSONAL INJURY OR DAMAGE TO THE TRANSAXLE,
HANDLING OF THE TRANSAXLE ASSEMBLY IS A TWO PERSON OPERATION.
WA R N I N G
THE TRANSAXLE ASSEMBLY IS VERY HEAVY. TO AVOID
PERSONAL INJURY OR DAMAGE TO THE TRANSAXLE, HANDLING OF THE TRANSAXLE ASSEMBLY IS A TWO PERSON OPERATION.
Page 558 of 947
Manual Control System (07.06)
Transmission (07.00)7-6-2 Workshop Manual May 2007
Installation
1. Install selector cable, connect to ball joint, install horseshoe clip.
2. Connect multiplug to reverse light switch, install multiplug in bracket.
3. Install reverse light harness clip in transaxle.
4. Install transaxle mounting brackets and hydra mounts, install and torque tighten new bolts (x8).
5. Align hydra mounts to subframe, lower lifter, install and torque tighten nuts (x2). Remove lifter.
6. Remove plugs, connect and torque oil cooler unions.
7. Apply thread lock to new Allen bolts.
8. Align drive shafts to transaxle flanges, clean and install plates (x6), install and torque tighten Allen bolts (x12).
9. Position earth lead to transaxle, install and torque tighten bolt.
10. Install shear plate, install bolts (x8), tighten bolts to correct torque.
11. Install centre heatshield, install bolts (x4), tighten bolts to correct torque.
12. Install centre and rear exhaust pipe assembly, align to both catalysts. tighten clamp nuts to correct torque.
13. Install subframe cross brace, install and torque tighten bolts (x4).
14. Install rear exhaust muffler (see Workshop Manual procedure 09.00.KA Silencer and Bypass Valve
Assembly - Remove for Access and Refit).
15. Install road wheel(s).
16. Lower vehicle on ramp, remove securing straps.
17. Position selector cable in bracket, install horseshoe clip.
18. Install selector cable ball jo int to gear lever mechanism.
19. Install panel assembly - console.
20. Connect vehicle battery.
21. Test drive vehicle.
22. Raise vehicle on ramp; Check transaxle oil level.
Page 562 of 947
Clutch Assembly (08.01)
8-1-2 Workshop Manual May 2007
Clutch (08.00)
Clutch Assembly (08.01)
Description
The clutch assembly consists of a balanced flywheel, a clutch
driven plate and a clutch cover.
The clutch is a single plate, diaphragm spring type assembly.
A concentric clutch slave cylinder is mounted around the
first motion shaft in the torque tube bell housing.
The clutch master cylinder is mounted on the engine
bulkhead and is operated directly by the clutch pedal.
A hydraulic connection from the master cylinder feeds
pressurised fluid to the slave cylinder. The slave cylinder has
an extension tube and bleed nipple extending from the left
side of the bell housing for bleeding the system after any
major work.
Specifications
Maintenance
Clutch and Flywheel Assembly-Renew
08.00.AA
Removal
1. Disconnect vehicle battery.
2. Raise vehicle on ramp.
3. Remove torque tube assembly (see Workshop Manual procedure 05.01.CA Torque Tube Remove for Access
and Refit).
4. Remove bolts (x2) from inspection cover to lower crankcase and remove cover. 5. Install special tool SKAM14546 OT to restrain flywheel
and install and tighten bolts (x2) (see Fig. 1).
6. Remove bolts (x6) from clutch cover to flywheel (see Fig.
2).
7. Release clutch cover from dowels, remove cover and collect drive plate.
Clutch Fluid
Castrol/Girling Universal Brake and Clutch fluid.
Clutch Assembly
Clutch and flywheel are separately balanced.
Clutch Plate
Single 267mm driven plate.
Torque Figures
DescriptionNmlb/ft
Flywheel Bolts
Tighten the bolts in sequence. Loosen
the bolts and then torque, in even
stages, in the same sequence. 100 -
120
74-
88.5
Clutch Bolts
Tighten x6 equally-spaced bolts, in-
turn, to pull-down the clutch evenly.
Then torque all bolts in sequence. 65-75 48-55
Starter Motor Bolts 42.5-
57.531.5-
42.5
Repair Operation Time (ROT)
Fig. 1
Fig. 2
Warning
The clutch assembly is heavy. Ensure the clutch
assembly is supported befo re removing final bolts.
Page 563 of 947
Clutch Assembly (08.01)
May 2007 Workshop Manual 8-1-3
8. Remove bolts (x8) from flywheel to crankshaft and discard bolts (see Fig. 3).
9. Remove bolts (x2) and collect special tool SKAM14546 OTC.
10. Release flywheel from dowels and remove flywheel.
Installation
1. Clean flywheel and mating face on crankshaft flange.
2. Inspect pilot bearing for wear.
3. Position flywheel and align to dowel(s) on crankshaft flange.
4. Install bolts (x8) and install special tool SKAM14546 OTC to restrain flywheel.
5. Tighten flywheel bolts in the correct sequence.
6. Clean clutch cover and drive plate.
7. Install clutch assembly on flywheel and align to dowels.
8. Install bolts (x8), insert clutch alignment tool and evenly tighten bolts to the correct torque.
9. Remove clutch alignment tool.
10. Remove bolts (x2) and collect tool.
11. Install inspection cover to crankcase and tighten bolts (x2).
12. Install torque tube assembly (see Workshop Manual procedure 05.01.CA Torque Tube Remove for Access
and Refit).
13. Lower vehicle on ramp.
14. Connect vehicle battery.
Slave Clutch Cylinder-Renew
08.00.AC
Removal
1. Disconnect vehicle battery.
2. Raise vehicle on ramp.
3. Remove torque tube (see Workshop Manual procedure 05.01.CA Torque Tube Remove for Access and Refit).
4. Release clips and remove bleed and supply pipes from slave cylinder.
5. Install clips in union
6. Loosen and remove pipe adaptors (x2) from slave cylinder (see Fig. 1).
7. Sportshift Only - Remove bolts (x2) securing clutch
position sensor to slave cylinder.
Fig. 3
Warning
The flywheel is heavy. Ensure the flywheel is supported
before removing.
Warning
The flywheel is heavy. Ensure the flywheel is supported
when installing.
Warning
The clutch assembly is heavy. Ensure the clutch
assembly is supporte d when installing.
Caution
The flywheel and pressure are a balanced assembly. Ensure alignment marks are aligned.
Repair Operation Time (ROT)
Warning
Always disconnect the battery earth (- ve) terminal first.
Warning
When raising the vehicle on a ‘two post’ ramp, ensure
that the rear end of the vehicle is securely strapped to
the ramp. Failure to strap the rear of the vehicle down may lead to the vehicl e falling off the ramp.
Caution
Always plug pipe ends to prevent ingress of dirt or moisture into the system.
Fig. 1
Page 569 of 947
Silencer Assembly (09.01)
Exhaust (09.00)9-1-4 Workshop Manual Issue 5, January 2010
Removal
1. Raise vehicle on ramp.
2. Remove rear exhaust silencer (refer to Workshop Manual procedure 09.00.KA Muffler & Bypass Valve
Assembly - Remove for Access & Refit).
3. Disconnect multiplugs (x2), HEGO sensors.
4. Release sensor lead from clip on heatshield.
5. Secure sufficient lengths of string to HEGO sensor multiplugs for assembly purposes.
6. Loosen LH and RH clamp nuts , catalysts to centre pipe.
7. With assistance, manoeuvre exhaust centre pipe assembly rearwards to release from catalysts.
8. Remove nuts (x3), catalyst to exhaust manifold.
9. With assistance, release and support weight of RH catalyst from exhaust manifold.
10. Manoeuvre HEGO sensor leads and remove cable tie. Release HEGO sensor leads from behind heat shield.
Remove string from HEGO multiplugs.
11. Remove catalyst assembly.
12. Remove and discard gasket.
13. Remove HEGO sensors (x2) from catalyst.
Installation
1. Clean catalyst, mating joint faces and HEGO sensors..
2. Install and tighten HEGO sensors (x2) to catalyst.
3. Apply proprietary exhaust sealant around pipe joints.
4. Install new gasket to exhaust manifold flange.
5. With assistance, position catal yst, secure string (x2) to
HEGO multiplugs, feed sensor leads behind heat shield.
Secue cable tie. Install catalyst to exhaust manifold.
6. Install and torque tighten nuts (x3), catalyst to exhaust manifold.
7. Align centre pipe asembly to catalyst, torque tighten
clamp nuts.
8. Remove string (x2), connect multiplugs (x2), HEGO sensors.
9. Secure sensor lead in clip on heatshield.
10. Install rear exhaus t silencer (refer to Workshop Manual
procedure 09.00.KA Muffler & Bypass Valve Assembly -
Remove for Access & Refit).
11. Lower vehicle on ramp.
LH Exhaust Manifold-Renew-Roadster
Only
Removal
1. Disconnect vehicle battery.
2. Raise vehicle on ramp. 3. Remove heatshield deflec
tor, front floor (refer to
Workshop Manual procedure 09.04.AA Heatshield -
Front Floor - Renew).
4. Remove LH front wheel arch liner (refer to Workshop Manual procedure 01.02.FB Wheel Arch Liner - Front -
LH - Renew).
5. Remove nuts (x8), securing manifold to cylinder head.
6. Remove exhaust manifold, remove and discard gasket.
Installation
1. Clean manifold and mating face on engine. Install new gasket to engine.
2. Install manfold to engine.
3. Install nuts (x8) securing manifold to cylinder head
(torque).
4. Install LH front wheel arch liner (refer to Workshop Manual procedure 01.02.FB Wheel Arch Liner - Front -
LH - Renew).
5. Install heatshield deflector, front floor (refer to Workshop Manual procedure 09.04.AA Heatshield -
Front Floor - Renew).
6. Lower vehicle on ramp.
7. Connect vehicle battery.
Heated Exhaust Gas Oxygen (HEGO)
Sensor - Remove and Install
Removal
1. Raise the vehicle and make it safe.
2. Release the two electrical connnectors for the Heated Exhaust Gas Oxygen (HEGO) sensor from the bracket.
3. Disconnect the two electrical connnectors from the HEGO sensor.
4. Move the two wiring harnesses for the HEGO sensor away.
5. Remove the two bolts that attach the bracket to the engine.
6. Remove the bracket.
7. Remove the two bolts that attach the heat shield to the torque tube.
8. Move the heat shield away.
Repair Operation Time (ROT)
Repair Operation Time (ROT)
ItemCode
Heated Exhaust Gas Oxygen (HEGO)
Sensor - Remove and Install 09.00.DB
WAR NI NG
THE EXHAUST SYSTEM WILL BE VERY HOT AFTER
OPERATION. LET THE EXHA UST COOL BEFORE YOU
DO WORK. IF YOU DO NO T, PESONAL INJURY CAN
OCCUR.
Page 571 of 947
Silencer Assembly (09.01)
Exhaust (09.00)9-1-6 Workshop Manual Issue 5, January 2010
2. Clean silencer and mating faces on rear pipes.
3. Remove Rear RH wheel arch liner (refer to Workshop Manual procedure 01.02.HB Wheel Arch Liner - Rear -
RH - Renew).
4. Remove rear undertray (refer to Workshop Manual procedure 01.02.PB Undertray - Rear - Renew).
5. Apply a proprietary exhaust sealant around all clamp joints
6. Remove Allen bolts (x2), loosen Allen bolts (x2), bumper diffuser to mounting brackets and remove diffuser.
7. Position silencer on lifter.
8. Install silencer, position rear hangers to body, install and torque tighten bolts (x4).
9. Remove Rear LH wheel arch liner.
10. Disconnect both by-pass valve vacuum lines.
11. Remove Allen bolts (x2), loosen Allen bolts (x2), bumper diffuser to mounting brackets and Remove diffuser.
12. Position front mountings to subframe, install and torque tighten bolts (x4).
13. Loosen clamp nuts (x2), remove stub pipes (x2).
14. Disconnect both by-pass valve vacuum lines.
15. Align silencer to rear pipes, install springs onto bolts (x4), install and torque tighten bolts (x4).
16. Remove bolts (x4), rear exha ust pipes to silencer. Collect
springs from bolts.
17. Loosen clamp nuts (x2), remove stub pipes (x2).
18. Install stub pipes (x2), centralise stub pipes to exhaust trim finisher. Torque ti ghten clamp nuts (x2).
19. Remove bolts (x4), securing LH and RH silencer rear
hanger brackets to body.
20. Remove bolts (x4), rear exhaust pipes to silencer and collect springs from bolts.
21. Check silencer to rear pipes for correct alignment and clearances.
22. Remove bolts (x4), silencer front mountings to subframe.
23. Remove bolts (x4), securing LH and RH silencer rear
hanger brackets to body.
24. Connect lines to both by-pass vacuum valves.
25. Position suitable lifter to support weight of silencer.
With assistance, remove silencer.
26. Remove bolts (x4), silencer front mountings to subframe.
27. Install rear bumper diffuser and install and tighten Allen
bolts (x4).
28. Install Rear RH wheel arch liner (refer to Workshop Manual procedure 01.02.HB Wheel Arch Liner - Rear -
RH - Renew).
Installation
1. Position suitable lifter to su pport weight of silencer. With
assistance, remove silencer.
2. Clean silencer and mating faces on rear pipes.
3. Install Rear LH wheel arch liner.
4. Apply a proprietary exhaust sealant around all clamp joints 5. Lower vehicle on ramp.
6. Position silencer on lifter. Install silencer, position rear
hangers to body, install and torque tighten bolts (x4).
7. Position front mountings to subframe, install and torque tighten bolts (x4).
8. Align silencer to rear pipes, install springs onto bolts (x4), install and torque tighten bolts (x4).
9. Install stub pipes (x2), centralise stub pipes to exhaust trim finisher and torque tighten clamp nuts (x2).
10. Check silencer to rear pipes for correct alignment and clearances.
11. Connect lines to both by-pass vacuum valves.
12. Install rear bumper diffuser and install and tighten Allen bolts (x4).
13. Install rear undertray (r efer to Workshop Manual
procedure 01.02.PB Undertray - Rear - Renew).
14. Lower vehicle on ramp.
Silencer and Bypass Valve Assembly-
Renew
Removal
1. Raise vehicle on ramp.
2. Coupe Only - Remove rear undertray (refer to
Workshop Manual procedure 01.02.PB Undertray -
Rear - Renew).
3. Roadster Only - Remove RH rear wheel arch liner (refer
to Workshop Manual procedure 01.02.HB Wheel Arch
Liner - Rear - RH - Renew).
4. Roadster Only - Remove LH rear wheel arch liner.
5. Remove Allen bolts (x2, loosen Allen bolts (x2), securing bumper diffuser to mounting brackets. Remove diffuser.
6. Disconnect both by-pass valve vacuum lines.
7. Loosen clamp nuts (x2), remove stub pipes (x2).
8. Remove bolts (x4), rear exha ust pipes to silencer. Collect
springs from bolts.
9. Remove bolts (x4), securing LH and RH silencer rear
hanger brackets to body.
10. Remove bolts (x4), muffler front mountings to subframe. Remove mountings from silencer.
Repair Operation Time (ROT)
ItemCode
Silencer and Bypass Valve Assembly-
Renew 09.00.KB
WAR NI NG
THE EXHAUST SYSTEM WILL BE VERY HOT AFTER
OPERATION. LET THE EXHA UST COOL BEFORE YOU
DO WORK. IF YOU DO NO T, PESONAL INJURY CAN
OCCUR.
WAR NI NG
GET THE AID OF ONE MORE PERSON WHEN YOU
REMOVE THE REAR EXHAUST SILENCER.
THE SILENCER IS HEAVY .
Page 572 of 947
Silencer Assembly (09.01)
Exhaust (09.00)
Issue 5, January 2010 Workshop Manual 9-1-7
11. Position suitable lifter to support weight of silencer.
With assistance, remove silencer.
12. Remove both rear rubber mountings and hanger brackets from silencer.
Installation
1. Clean silencer and mating faces on rear pipes and stub pipes.
2. Install both rear rubber mountings and hanger brackets to silencer.
3. Position silencer on lifter . Install silencer, position
hangers, install and tighten bolts (x4).
4. Install front mountings to silencer, install and tighten bolts (x4).
5. Align silencer to rear pipes. Install springs (x4), and torque tighten bolts (x4).
6. Install and align stub pipes (x2) to silencer and trims in bumper. Align and tighten clamp bolts.
7. Check silencer to rear pipes for correct alignment and clearances.
8. Install stub pipes (x2), insta ll clamps (x2), centralise stub
pipes to exhaust trim finisher, torque tighten clamp nuts
(x2).
9. Check silencer to rear pipes for correct alignment and clearances.
10. Connect lines to both by-pass vacuum valves.
11. Install rear bumper diffuse r. Install and tighten Allen
bolts (x4).
12. Roadster Only - Install RH rear wheel arch liner (refer to
Workshop Manual procedure 01.02.HB Wheel Arch
Liner - Rear - RH - Renew).
13. Roadster Only - Install LH rear wheel arch liner.
14. Coupe Only - Install rear undertray (refer to Workshop
Manual procedure 01.02.PB Undertray - Rear - Renew).
15. Lower vehicle on ramp.
Exhaust Rear Silencer Mounting Rubber-
Renew
Removal
1. Raise vehicle on ramp. 2. Remove Allen bolts (x4), bumper diffuser to mounting
brackets. Remove diffuser, collect mounting brackets.
3. Remove bolts (x2), securing silencer rear hanger brackets to body.
4. Release/remove rubber mounting and hanger bracket from silencer bracket.
5. Remove rubber mounting from hanger bracket.
Installation
1. To aid assembly, apply liquid soap to rubber mounting .
2. Install rubber mounting on hanger bracket.
3. Install rubber mounting on muffler bracket.
4. Align hanger bracket to body, install and torque tighten bolts (x2).
5. Position mounting brackets, install bumper diffuser, install and torque tighten Allen bolts (x4).
6. Lower vehicle on ramp.
Exhaust System-Renew
1. Disconnect vehicle battery.
2. Raise vehicle on ramp.
3. Remove RH exhaust manifold.
4. Remove RH front wheel arch liner (refer to Workshop Manual procedure 01.02.GB Wheel Arch Liner - Front -
RH - Renew).
5. Remove LH front wheel arch liner (refer to Workshop
Manual procedure 01.02.FB Wheel Arch Liner - Front -
LH - Renew).
6. Remove heatshield deflector, front floor (refer to Workshop Manual procedure 09.04.AA Heatshield -
Front Floor - Renew).
7. Loosen EGR pipe in valve.
8. Remove (nuts x2) EGR pipe from manifold, discard
gasket and tie aside.
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)
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.
Repair Operation Time (ROT)
Page 573 of 947
Silencer Assembly (09.01)
Exhaust (09.00)9-1-8 Workshop Manual Issue 5, January 2010
9. Remove nut (x8) securing RH exhaust manifold to cylinder head (refer to Fig. 1).
10. Remove nut (x2) on RH engine mounting.
11. Raise engine by approximately 25mm.
12. Remove RH exhaust manifold from vehicle and discard
gasket.
13. Remove heatshield from manifold (bolts x4)
14. Remove nuts (x8) securing LH exhaust manifold to
cylinder head.
15. Remove exhaust manifold, remove and discard gasket.
Installation
1. Clean LH exhaust manifold and mating face on cylinder head. Install new manifold gasket.
2. Install LH exhaust manifold to cylinder head.
3. Install and torque tighten nuts (x8) securing exhaust manifold to cylinder head.
4. Clean exhaust manifold and mating face on engine. Install new gasket to engine.
5. Install heatshield to manifold (bolts x4)
6. Install RH exhaust mani fold to cylinder head.
7. Install nut (x8) securing manifold to cylinder head
(torque).
8. Lower engine.
9. Install nuts (x2) on engine mounts (torque).
10. Install (nuts x2) EGR pipe from manifold, clean mating face and fit new gasket (torque).
11. Install heatshield deflector, front floor (refer to Workshop Manual procedure 09.04.AA Heatshield -
Front Floor - Renew).
12. Tighten EGR pipe in valve (torque).
13. Install RH front wheel arch liner (refer to Workshop Manual procedure 01.02.GB Wheel Arch Liner - Front -
RH - Renew
14. Install LH wheel arch liner (refer to Workshop Manual procedure 01.02.FB Wheel Arch Liner - Front - LH -
Renew).
15. Lower vehicle on ramp. 16. Connect vehicle battery.
Exhaust System (Excluding Manifold/
Downpipes)-Renew
Removal
1. Raise vehicle on ramp.
2. Remove undertrays - vehicle set (refer to Workshop
Manual procedure 01.02.PD Undertrays - Vehicle Set -
Renew).
3. Remove Allen bolts(x4), bumper diffuser to mounting brackets. Remove diffuser
4. Disconnect both by-pass valve vacuum lines.
5. Remove bolts (x4), securing LH and RH silencer rear
hanger brackets to body. Remove hanger brackets.
6. Remove bolts (x4), rear exha ust pipes to silencer. Collect
springs from bolts
7. Remove bolts (x4), silencer front mountings to subframe. Remove mountings from silencer.
8. Position suitable lifter to support weight of silencer. with assistance, remove silencer.
9. Mark rear stub pipes to si lencer for assembly purposes.
10. Loosen clamps (x2), rear stub pipes to silencer. Remove stub pipes and clamps.
11. Remove bolts (x4), remove rear subframe cross brace.
12. Loosen clamps (x2), release RH and LH rear pipes from centre pipe.
13. Remove rear pipes through subframe.
14. Loosen clamps (x2), centre pipe to LH and RH catalysts.
15. Coupe Only - Release centre pipe from mountings, LH
and RH catalysts, remove centre pipe.
16. Roadster Only - Remove centre exhaust mounting bolts
(x4).
17. Release LH and RH catal ysts, remove centre pipe.
18. Disconnect multiplugs (x4), from each catalyst.
19. Coupe Only - Secure sufficient lengths of string to
HEGO sensor multiplugs for assembly purposes.
Figure 1
A090069
Repair Operation Time (ROT)
ItemCode
Exhaust System (Excluding Manifold/
Downpipes)-Renew 09.00.NB
WAR NI NG
TO AVOID PERSONAL INJURY, I.E. SEVERE BURNS TO
THE SKIN, ALLOW EXHAUS T SYSTEM TO COOL
DOWN BEFORE REMOVING EXHAUST SYSTEM COMPONENTS.
WAR NI NG
GET THE AID OF ONE MORE PERSON WHEN YOU
REMOVE THE REAR EXHAUST SILENCER.
THE SILENCER IS HEAVY .
Attach lengths of string to th e HEGO sensor multiplugs. This
enables routing the HEGO sensor harness behind the exhaust heat shield on assembly.
Page 577 of 947
Pipes and Supports (09.03)
Exhaust System (09.00)9-2-2 Workshop Manual May 2007
5. Install centre pipe to both catalysts and centre mountings. Do not torque clamp nuts at this stage.
6. Install pipe assembly exha ust rear - LH (refer to
Workshop Manual procedure 09.00.JB Pipe Assembly -
Exhaust - Rear - LH - Renew).
7. Install pipe assembly exhaust rear - RH (refer to Workshop Manual procedure 09.00.HB Pipe Assembly
- Exhaust - Rear - RH - Renew).
8. Align and torque tighten exhaust system nuts/bolts.
9. Lower vehicle on ramp.
RH Exhaust Manifold-Renew
Removal
1. Disconnect vehicle battery.
2. Raise vehicle on ramp.
3. Remove RH front wheel arch liner (refer to Workshop Manual procedure 01.02.GB Wheel Arch Liner - Front -
RH - Renew).
4. Loosen EGR pipe in valve.
5. Remove heatshield deflector, front floor (refer to Workshop Manual procedure 09.04.AA Heatshield -
Front Floor - Renew).
6. Remove (nuts x2) EGR pipe from manifold, discard
gasket and tie aside.
7. Remove nut (x8) securing manifold to cylinder head
(refer to Fig. 1).
8. Remove nut (x2) on engine mountings.
9. Raise engine by approximately 25mm. 10. Remove exhaust manifold from vehicle and discard
gasket.
11. Remove heatshield from manifold (bolts x4)
Installation
1. Clean exhaust manifold and mating face on engine. Install new gasket to engine.
2. Install heatshield to manifold (bolts x4)
3. Install manifold to engine.
4. Install nut (x8) securing manifold to cylinder head.
5. Lower engine.
6. Install nuts (x2) on engine mounts.
7. Install (nuts x2) EGR pipe from manifold, clean mating face and fit new gasket (torque).
8. Install heatshield deflector, front floor (refer to Workshop Manual procedure 09.04.AA Heatshield -
Front Floor - Renew).
9. Tighten EGR pipe in valve (torque).
10. Install RH front wheel arch liner (refer to Workshop
Manual procedure 01.02.GB Wheel Arch Liner - Front -
RH - Renew).
11. Lower vehicle on ramp.
12. Connect vehicle battery.
LH Exhaust Manifold-Renew
Removal
1. Disconnect vehicle battery.
2. Raise vehicle on ramp.
3. Remove heatshield deflec tor, front floor (refer to
Workshop Manual procedure 09.04.AA Heatshield -
Front Floor - Renew).
4. Remove LH front wheel arch liner (refer to Workshop Manual procedure 01.02.FB Wheel Arch Liner - Front -
LH - Renew).
Repair Operation Time (ROT)
A090069
Repair Operation Time (ROT)
ItemCode
Exhaust Manifold-Renew LH09.00.CB
WAR NI NG
TO AVOID PERSONAL INJURY, I.E. SEVERE BURNS TO
THE SKIN, ALLOW EXHAUS T SYSTEM TO COOL
DOWN BEFORE REMOVING EXHAUST SYSTEM COMPONENTS.
Page 578 of 947
Pipes and Supports (09.03)
Exhaust System (09.00)
May 2007 Workshop Manual 9-2-3
5. Remove nuts (x8), securing manifold to cinder head
(refer to Fig. 1).
6. Remove exhaust manifold, remove and discard gasket.
Installation
1. Clean manifold and mating face on engine and install
new gasket to engine.
2. Install manifold to engine.
3. Install nuts (x8) securing manifold to cylinder head.
4. Install LH front wheel arch liner (refer to Workshop Manual procedure 01.02.FB Wheel Arch Liner - Front -
LH - Renew).
5. Install heatshield deflector, front floor (refer to Workshop Manual procedure 09.04.AA Heatshield -
Front Floor - Renew).
6. Lower vehicle on ramp.
7. Connect vehicle battery.
RH Exhaust Manifold Gasket-Renew
Removal
1. Remove wheel arch liner (refer to Workshop Manual procedure 01.02.GB Wheel Arch Liner - Front - RH -
Renew).
2. Loosen EGR pipe in valve.
3. Remove heatshield deflector, front floor (refer to Workshop Manual procedure 09.04.AA Heatshield -
Front Floor - Renew).
4. Remove nuts (x2), EGR pipe to manifold, discard gasket
and tie EGR pipe aside. 5. Remove nut (x8) securing ex
haust manifold to cylinder
head.
6. Remove nuts (x2) on engine mountings.
7. Raise engine by approximately 25mm. (care to be taken as inlet manifold can foul).
8. Remove exhaust manifold from vehicle and discard gasket.
Installation
1. Install new gasket to engine, clean mating face on engine.
2. Install manifold to engine.
3. Install nut (x8) securing manifold to cylinder head
(torque).
4. Lower engine.
5. Install nuts (x2) on engine mounts (torque).
6. Install (nuts x2) EGR pipe from manifold, clean mating face and fit new gasket (torque).
7. Install heatshield deflector, front floor (refer to Workshop Manual procedure 09.04.AA Heatshield -
Front Floor - Renew).
8. Tighten EGR pipe in valve (torque).
9. Install wheel arch liner (r efer to Workshop Manual
procedure 01.02.GB Wheel Arch Liner - Front - RH -
Renew).
LH Exhaust Manifold Gasket-Renew
Removal
1. Remove heatshield deflector, front floor (refer to Workshop Manual procedure 09.04.AA Heatshield -
Front Floor - Renew).
2. Remove LH wheel arch liner (refer to Workshop Manual procedure 01.02.FB Wheel Arch Liner - Front - LH -
Renew).
3. Remove nut (x8) securing manifold to cylinder head.
4. Remove manifold from vehicle and discard gasket.
Installation
1. Install new gasket to engine, clean mating face on engine.
2. Install manifold to engine.
3. Install nut (x8) securing manifold to cylinder head
(torque).
4. Install LH wheel arch liner (refer to Workshop Manual procedure 01.02.FB Wheel Arch Liner - Front - LH -
Renew).
Fig. 1
Repair Operation Time (ROT)
302306BA090070
Repair Operation Time (ROT)