air condition ASTON MARTIN V8 VANTAGE 2010 Workshop Manual

Contents
Issue 5, January 2010 Workshop Manual 0-0-3
V8 Vantage Workshop Manual
Contents
IntroductionWelcome .............................................................. 0-0-6
Safety Precautions ................................................. 0-0-7
Lifting and Jacking ................................................. 0-0-9
Vehicle Recovery ................................................ 0-0-10
Vehicle Identification Number ............................ 0-0-11
Body System (01.00) Body Structure (01.01) .......................................... 1-1-4
Front End System (01.02) ...................................... 1-2-1
Body Closures (01.03) ........................................... 1-3-1
Interior Trim (01.05) ............................................. 1-4-1
Exterior Trim (01.08) ............................................. 1-8-1
Mirrors (01.09) ...................................................... 1-9-1
Seating (01.10).................................................... 1-10-1
Glass, Frame and Mechanism (01.11) .................. 1-11-1
Instrument Panel (IP) (01.12) . .............................. 1-12-1
Handles and Lock Mechanisms (01.14) ............... 1-14-1
Wipers and Washer System (01.16)..................... 1-16-1
Convertible Roof and Roof Opening
Subsystem (01.17)................ ...............................1-17-1
Bumpers (01.19) ................................................. 1-19-1
Restraining Devices (01.20) .... ............................. 1-20-1
Frame and Mounting (02.00) Subframes (02.03) ................................................. 2-1-2
Engine System (03.00) Engine Assembly....................................................3-0-3
Engine Structure (03.01)........................................ 3-1-1
Lubrication System (03.02).................................... 3-2-1
Cooling System (03.03) ......................................... 3-3-1
Fuel Charging System (03.04) ................................ 3-4-1
Accessory Drive System (03.05)............................. 3-5-1
Engine Cranking System (03. 06) ............................ 3-6-1
Valve Train (03.09) ............................................... 3-9-1
Engine Sealing (03.10)......................................... 3-10-1
Power Conversion (03.11)................................... 3-11-1
Evaporative Emissions (03.13) ............................. 3-11-1
Engine Management System (0 3.14).................... 3-14-1
Throttle Control (03.16) ...... ................................ 3-16-1
Foot Operated Control (03.18)............................ 3-18-1
Suspension (04.00) Road Wheel Alignment (04.00) ............................. 4-0-2
Front Suspension (04.01)....................................... 4-1-1
Rear Suspension (04.02)........................................ 4-2-1
Shock Absorber System (04.03) ............................. 4-3-1
Road Wheels and Tyres (04.04) ............................ 4-4-1
Driveline (05.00) Driveshaft (05.01) ................................................. 5-1-2
Halfshafts (05.05) .................................................. 5-2-1 Brake System (06.00)
Front Disc Brake (06.03) ....................................... 6-3-2
Rear Disc Brakes (06.04) ....................................... 6-4-1
Hand Brake (06.05) .............................................. 6-5-1
Brake Actuation System (06.06 ) ............................ 6-6-1
Power Brake System (06.07) ................................. 6-7-1
Anti-lock Braking System (06.09)........................... 6-9-1
Transmission (07.00) Transmission Cooling (07.02) ................................ 7-0-2
Manual Transmission (07.03) ................................ 7-3-1
Automatic Control System (07.05)......................... 7-5-1
Manual Control System (07.06) ............................. 7-6-1
Automatic Shifting Subsytem (07.11) .................. 7-11-1
Clutch (08.00) Clutch Controls (08.02) ......................................... 8-1-2
Exhaust (09.00) Exhaust Overview ................................................. 9-1-2
Silencer Assembly (09.01) ..................................... 9-1-3
Pipes and Supports (09.03) ................................... 9-2-1
Exhaust Protection (09.04) .................................... 9-3-1
Fuel (10.00) Fuel Tank and Lines (10.01) ................................ 10-1-2
Steering (11.00) Steering Gear (11.01) .......................................... 11-1-2
Power Steering (11.02)........................................ 11-2-1
Steering Column (11.04) ..................................... 11-4-1
Steering Column Switches (1 1.05) ....................... 11-5-1
Steering Wheel (11.06) ....................................... 11-6-1
Climate Control (12.00) Body Ventilation system (12.01) .......................... 12-1-2
Heater System (12.02) ........................................ 12-2-1
Air Conditioning (A/C) System (12.03) ................. 12-3-1
Information, Gauge and Warning (13.00) Instrument Cluster (13.01) .................................. 13-1-2
Power Supply (14.00) Battery System (14.01) ........................................ 14-1-2
Alternator and Regulator System (14.02) ............. 14-2-1
Vehicle Entertainment (15.00) Audio System (15.01)................................ ..........15-1-2
Antenna (15.02).................................................. 15-2-1
Vacuum Distribution (16.00) Body Vacuum System (16.01) ............................. 16-1-2
Lighting (17.00) Front Lights (17.01) ............................................. 17-1-2
Interior Lighting (17.02) ...................................... 17-2-1
Rear Lights (17.03) .............................................. 17-3-1
Lighting Mechanisms (17.04). .............................. 17-4-1

Contents
Issue 5, January 2010 Workshop Manual 0-0-5
Introduction
Contents ................................................................. 0-3
Welcome................................................................ 0-0-6 Chapters ................................................................. 0-6Chapter Navigation ................................................ 0-6
Page Numbering ..................................................... 0-6
Systems Classification Coding ................................ 0-6
Special Tools.......................................................... 0-0-6 Location References................................................ 0-6
Warnings, Cautions and Notes .............................. 0-0-6 Repairs and Replacements ..................................... 0-6
Safety Precautions ................................................. 0-0-7 Battery Disconnection ............................................ 0-7
Air Conditioning (A/C) System ................................ 0-7
Chemical Handling and Storage ............................. 0-7
Electrical Equipment .............................................. 0-0-7 Exhaust Fumes ........................................................ 0-7
Fire Precautions ...................................................... 0-7
Tools and Equipment............................................. 0-0-8 Used Engine Oil...................................................... 0-8
Health protection precautions................................ 0-8
Environmental Protection ....................................... 0-8
Lifting and Jacking ................................................. 0-0-9 Safety ...................................................................... 0-9
Jacking Points ........................................................ 0-0-9
Lifting ..................................................................... 0-0-9 Workshop Hoist ..................................................... 0-9
Workshop Jack....................................................... 0-9
Stands .................................................................... 0-9
Vehicle Recovery.................................................. 0-0-10 General ................................................................. 0-10
Transporting ......................................................... 0-10Suspended Towing............................................... 0-10
Adhere to Towing Regulations.............................. 0-10
Towing by Another Vehicle .................................. 0-10
Vehicle Identification Number ............................ 0-0-11
VIN Number Location .......................................... 0-11
Engine Number..................................................... 0-12
Gearbox Number .................................................. 0-12

Safety Precautions
Issue 5, January 2010 Workshop Manual 0-0-7
Safety Precautions
All service workshops are a source of potential danger and
repair work should only be performed by technically trained
staff following procedures detailed in this manual. A safety
conscious approach to the performance of all service
procedures must be observed at all times. Statutory
requirements governing all aspects of health and safety at
work including directives for the proper use of materials and
equipment must be implemented.
The following contains a list of particular safety precautions
which should be observed; it is not intended to be
exhaustive.
Battery Disconnection
When a service manual procedure requires the vehicle
battery to be disconnected - always physically disconnect
the vehicle battery earth (Negative) lead.
Do not use the ‘Battery Disconnect Switch’.
After reconnecting the vehicle battery the following items
will have to be reset or re-learnt:
•Radio pre-sets
•Windows
• DTCs will be lost
Air Conditioning (A/C) System
Do not break into the A/C refrigeration system until the
refrigerant has been evacuated using the procedure detailed
in this manual. Do not disconne ct any A/C refrigerant system
pipes unless trained and instructed to do so. The refrigerant
used can cause blindness if allowed to contact your eyes.
Chemical Handling and Storage
Chemicals used in the servicing of motor vehicles include
acids, adhesives, antifreeze, brake fluids, coolants, grease,
oil, paint, resin and solvents. Exposure to certain chemicals
through direct contact or inhalation can be fatal.
Potential hazards may also be present through the incorrect
use, storage and handling of chemicals causing a fire risk.
The following precaution s should be observed.
• Strictly adhere to handling and safety information found on containers and labels.
• Do not store chemicals in unlabelled or incorrectly labelled containers.
• Containers used for storing chemicals should not be left open; there is a risk of spilling , or evaporation of fumes
which may be inflammable or toxic.
• Do not mix chemicals unless instructed to do so following manufacturers guidelines.
• Do not inhale chemical materials to determine identity, they may be toxic.
• Do not use petrol, kerosene, diesel fuel, gas oil, thinners or solvents for washing skin.
• Containers whose capacity is over 25 litres (5 gallons) require a bund wall in order to contain spillages. • Chemicals based on solvents such as paint should not be
sprayed in a confined space; work areas used for such
operations should be well ve ntilated and fume extraction
equipment should be utilised.
• Ensure that adequate ventilation is provided when volatile de-greasing agents are being used.
• Avoid splashing the skin, eyes and clothing .
• Clean chemicals from the skin and clothing as soon as
possible after soiling .
• Wear protective clothing such as goggles, non porous gloves and apron when handling battery acid and other
corrosive and toxic substances.
Electrical Equipment
• Ensure that electrical equipment is in safe working order before use.
• Inspect power leads of all mains electrical equipment for damage and security, and check that it is properly earthed.
• Ensure that electrical equipment is protected by a fuse of the correct current rating .
• Disconnect the battery before commencing repair operations to the electrical sy stem, fuel system and engine
or when working beneath the vehicle.
Exhaust Fumes
Engines should not be run in confined spaces as exhaust
fumes contain harmful and to xic substances including
carbon monoxide which can prove fatal if inhaled. Engines
must only be run where there is fume extraction equipment
in operation or where there is adequate ventilation.
Fire Precautions
• Ensure that a suitable form of fire extinguisher is conveniently located near the work area.
• Keep oils, solvents and combustible materials away from naked flames and other sources of ignition.
• Ensure that NO SMOKING signs are posted around areas where combustible materials and vapour may be present
and ensure that the warnings are strictly observed.
• Ensure that dry sand is availabl e to soak up any spillage of
fuel or other flammable solutions.
• Fume extraction equipment must be available and in full working order to remove combustible and toxic vapours.
• All personnel should be aware of the fire drill procedures and precautions. WAR NI NG
DO NOT SMOKE IN THE VICINITY OF VOLATILE DE- GREASING AGENTS.
WAR NI NG
FUME EXTRACTION EQUIPMENT MUST BE IN
OPERATION WHEN SOLVENTS ARE USED E.G. TRICHLOROETHANE, WHITE SPIRIT, SBP3,
METHYLENE CHLORIDE, PERCHLORETHYLENE.

Seating (01.10)
Body System (01.00)
Issue 4, November 2008 Workshop Manual 1-7-1
Body System (01.00)
Seating (01.10)
Description
The front seats are installed with the following features:
• Integral side airbags
•Head restraints
• Safety belt reel pretensioner
• Electrically adjustable seat positioning and lumbar support
• Heated seat (optional)
Heated Seats
The heated seat system comprises:
• Heated seat switches
• Backrest heater element
• Cushion heater element and thermostat
The heated seat function permits the electrical heating of the
seat back and cushion on the driver and front passenger
seats. The heating system of each seat is selected by separate
switches located on the inside of each seat base.
Once the heated seat function has been activated, it will
operate until one of the following conditions have been
satisfied:
• A fixed period of time has expired (10 minutes)
• If the engine is not running and the ignition key is removed
• A malfunction is detected by the heated seat module
Confirmation that the heated seat function is active is
indicated by the illumination of an amber light on the
switch.
Specifications Maintenance
RH/LH Front Seat - Remove and Install
Remove
1. Power seat fully forward.
2. Remove bolts (x2), securing rear of seat to seat rails.
3. Power seat fully rearwards.
4. Disconnect vehicle battery.
5. Remove bolt securing se
at belt to seat frame.
6. Remove bolts (x2), securing front of seat to seat rails.
7. Tip the seat forwards and disconnect multiplugs (x4).
8. Protect sill plate and trim prior to seat removal.
9. With assistance, remove seat assembly.
Install
1. With assistance, Install seat in the vehicle.
2. Position seat belt to seat frame, install and torque tighten bolt.
3. Tip the seat forwards and connect multiplugs (x4).
4. Position seat onto seat rails.
5. Remove sill plate protection.
6. Connect vehicle battery.
7. Install front bolts (x2. Power seat forward and install rear bolts (x2). Torque tighten bolts (x4).
Front Seat Squab Cover Assembly (Each,
Pre-08MY) - Remove and Install
Remove
1. Remove seat (see Workshop Manual procedure 01.10.AB Seat Assembly - Front - LH - Remove for
Access and Refit).
Torque Figures
DescriptionNm
Seat mountings 20-25
Seatbelt 15-20
Repair Operation Time (ROT)
Repair Operation Time (ROT)

Instrument Panel (IP) (01.12)
Body System (01.00)
Issue 5, January 2010 Workshop Manual 1-9-1
Body System (01.00)
Instrument Panel (IP) (01.12)
Specifications
Maintenance
Instrument Panel - Renew
Removal
1. Disconnect vehicle battery.
2. Drain cooling system (see Workshop Procedure 03.03.AD Coolant - Drain and Refill).
3. Evacuate air conditioning system (see Workshop Procedure 12.03.FA Tank - Receiver Drier - Renew).
4. Remove RH door (see Work shop Procedure 01.03.EA
Door Assembly - RH - Remo ve for Access and Refit).
5. Remove LH front seat (see Workshop Manual 01.10.AB
Seat Assembly - Front - LH - Remove for Access and
Refit).
6. Remove RH front seat (see Workshop Manual 01.10.AA Seat Assembly - Front - RH - Remove for Access and
Refit). 7. Remove tread plate badges - screws x2 (see Figure1).
8. Remove screws (x12) 6 each
side and remove LH and
RH side tread plates.
9. Release door seal from d oor aperture (see Figure 2).
Torque Figures
DescriptionNm
IP Mountings 22.5
Glue pot bolts 8
Blower motor to bulkhead 10-14
Repair Operation Time (ROT)
01-12-013
Figure 1
Figure 2

Instrument Panel (IP) (01.12)
Body System (01.00)1-9-6 Workshop Manual Issue 5, January 2010
39. Install LH front seat (see Workshop Manual 01.10.AB Seat Assembly - Front - LH - Remove for Access and
Refit).
40. Fill cooling system (see Workshop Manual 03.03.AD
Coolant - Drain and Refill).
41. Re-charge air conditioni ng system (see Workshop
Manual 12.03.FA Tank - Receiver Drier - Renew).
42. Connect vehicle battery.
Airbag Panel and Door Assembly -
Renew
Removal
1. Remove glovebox assembly (see Workshop Manual
procedure 01.12.AL Glovebox Assembly - Renew).
2. Remove glovebox shield (see Figure 1).
3. Remove the bolts (x3) that secure the airbag panel and
door assembly plate to the chassis (see Figure 2)
.
4. Remove airbag panel and d oor assembly (5 clips) (see
Figure3).
Installation
1. Install airbag panel and door assembly (5 clips).
2. Through glovebox aperture, install support right-angled bar and secure bolts (x3).
3. Remove and clean double-sided taped from glovebox shield, apply new tape and install.
4. Install glovebox assembly (see Workshop Manual procedure 01.12.AL Gloveb ox Assembly - Renew).
Glovebox Assembly - Renew
Removal
1. Remove passenger lower panel assembly (5 clips and
multiplug).
2. Remove the securing screws holding the glove box hinge to the chassis (x2).
3. Support the glove box and locate the latch mechanism.
4. Using a suitable tool press the latch mechanism to release the glove box.
5. Support the glove box and detach the buffer cord from the glove box.
Installation
1. Support glovebox and attach the buffer cord (ensure the cord is through correct aperture).
2. Install glovebox into aperture and press top to latch.
3. Align the glovebox hinge an d secure with screws (x2)
including spacers between the hinge and chassis.
4. Install passenger lower panel assembly (5 clips and 1 multiplug).
Repair Operation Time (ROT)
Figure 3
Repair Operation Time (ROT)
ItemCode
Glovebox Assembly-Renew 01.12.AL

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

Engine Structure (03.01)
3-1-14Workshop ManualIssue 4, November 2008
14. Inspect cylinder head face for warpage, across centre
and from corner to corner.
15. Check condition and measure free length of valve springs.
16. Decarbonise combustion chambers and exhaust ports.
17. Measure valve stem diameters.
18. Use new valves and check valve guide clearance.
Installation
1. Clean cylinder head face and inlet/exhaust manifold faces. Use and air line to completely dry cylinder head
surfaces.
2. Lubricate and install intake and exhaust valves (x16).
3. Install valve stem oil seals.
4. Install valve springs and collars.
5. Using valve spring compressor, compress valve spring, install collets.
6. Release/remove spring compressor.
7. Repeat procedure for remaining valve assemblies.
8. Install selective tappet buckets in their original fitted positions.
9. Lubricate intake camshaft bearings and journals with clean engine oil.
10. Install intake camshaft, install bearing caps (x5), install bolts (x10).
11. Torque tighten bearing cap bolts in the correct sequence.
12. Lubricate exhaust camshaft be arings and journals with
clean engine oil.
13. Install exhaust camshaft, install bearing caps (x5), install bolts (x10).
14. Torque tighten bearing cap bolts in the correct sequence.
15. Install camshaft sprocket Torx bolts in intake and exhaust camshafts.
16. Rotate intake camshaft clockwise, check and log each valve clearance using feeler gauges.
17. Calculate the correct tappet bucket grade.
18. Repeat procedure for exhaust valve clearances.
19. Remove bearing cap bolts (x10), remove bearing caps (x5), remove intake camshaft.
20. Remove tappet buckets, install selected tappet buckets.
21. Repeat procedure for exhaust valve clearances.
22. Install intake camshaft, install bearing caps (x5), install bolts (x10).
23. Torque tighten bearing cap bolts in the correct sequence.
24. Rotate intake camshaft clockwise, re-check each valve clearance using feeler gauges.
25. Repeat procedure and re-check exhaust valve clearances.
26. Remove camshaft sprocket Torx bolts (x2).
27. Remove bearing cap bolts (x10), remove bearing caps (x5), remove intake camshaft. 28. Remove bearing cap bolts (x10), remove bearing caps
(x5), remove exhaust camshaft.
29. Clean EGR tube.
30. Install new gasket, install EGR tube to cylinder head, install and torque tighten Torx screws (x2).
31. Clean Knock sensors (x2).
32. Install knock sensors (x2) to cylinder head, install and torque tighten bolts (x2).
33. Clean camshaft timing sensor.
34. Install camshaft timing sensor, install and torque tighten bolt.
35. Install spark plugs.
36. Install cylinder head gasket RH (see Workshop Manual procedure 03.01.GU Gasket - Cylinder Head - RH -
Renew).
Cylinder Head (Engine Set) - Overhaul
Removal
1. Remove cylinder head gaskets - engine set (see Workshop Manual procedure 03.10.AL Gasket -
Cylinder Head - Engine Set - Renew).
2. Remove Torx screws (x4) securing EGR tubes to cylinder heads, remove tubes.
3. Remove and discard gaskets.
4. Remove bolts (x2) securing camshaft timing sensors to cylinder heads, remove sensors.
5. Remove bolts (x4) securing knock sensors (x4) to cylinder heads, remove sensors.
6. Remove spark plugs from cylinder heads (x8).
7. Remove selective tappet buckets, keep in their fitted order.
8. Position valve spring compressor, compress valve springs.
9. Remove collets, release/remove spring compressor, collect collars and valve springs.
10. Remove valves from cylinder heads.
11. Remove valve stem oil seals.
12. Keep valves and springs in their fitted order.
13. Inspect cylinder head face for warpage, across centre and from corner to corner.
14. Check condition and measure free length of valve springs.
15. Decarbonise combustion chambers and exhaust ports.
16. Use new valves and check valve guide clearances.
Installation
1. Clean cylinder head face and inlet/exhaust manifold faces. Use and air line to completely dry cylinder head
surfaces.
Repair Operation Time (ROT)
ItemCode
Cylinder Head (Engine Set)-Overhaul LHD03.01.GZ
Cylinder Head (Engine Set)-Overhaul RHD03.01.FZ

Engine Structure (03.01)
Issue 4, November 2008Workshop Manual 3-1-15
2. Lubricate and install intake and exhaust valves (x16).
3. Install valve stem oil seals.
4. Install valve springs and collars.
5. Using valve spring compressor, compress valve spring,
install collets.
6. Release/remove spring compressor.
7. Install selective tappet buckets in their original fitted positions.
8. Lubricate intake and exha ust camshaft bearings and
journals with clean engine oil.
9. Install intake and exhaust camshafts, install bearing caps (x20), install bolts (x40).
10. Torque tighten bearing cap bolts in the correct sequence.
11. Install camshaft sprocket Torx bolts in intake and exhaust camshafts.
12. Rotate intake camshaft cl ockwise, check and log each
valve clearance using feeler gauges.
13. Calculate the correct tappet bucket grade.
14. Remove bearing cap bolts (x40), remove bearing caps
(x20), remove intake and exhaust camshafts.
15. Remove tappet buckets, install selected tappet buckets.
16. Install intake and exhaust camshafts, install bearing caps (x20), install bolts (x40).
17. Torque tighten bearing cap bolts in the correct sequence.
18. Rotate intake and exhaus t camshafts clockwise, re-
check each valve clearance using feeler gauges.
19. Remove camshaft sprocket Torx bolts (x4).
20. Remove bearing cap bolts (x40), remove bearing caps
(x20), remove intake and exhaust camshafts.
21. Clean EGR tubes.
22. Install new gaskets, install EGR tubes to cylinder heads, install and torque tighten Torx screws (x4).
23. Clean Knock sensors (x4).
24. Install knock sensors (x4) to cylinder head, install and torque tighten bolts (x4).
25. Clean camshaft timing sensors.
26. Install camshaft timing sensor, install and torque tighten bolt.
27. Install spark plugs.
28. Install cylinder head gaskets - engine set (see Workshop Manual procedure 03.10.AL Gasket - Cylinder Head -
Engine Set - Renew).
Valve Set (Engine Set) - Renew (including
de-coke)
Removal
1. Remove cylinder head gaskets - engine set (see Workshop Manual procedure 03.10.AL Gasket -
Cylinder Head - Engine Set - Renew).
2. Remove spark plugs (x8).
3. Remove selective tappet buckets, keep in their fitted order.
4. Position valve spring compressor, compress valve spring.
5. Remove collets, release/remove spring compressor, collect collar and valve spring.
6. Remove valves from cylinder.
7. Remove valve stem oil seals.
8. Keep valves and springs in their fitted order.
9. Inspect cylinder head face for warpage, across centre and from corner to corner.
10. Check condition and measure free length of valve springs.
11. Decarbonise combustion chambers and exhaust ports.
12. Use new valves and check valve guide clearances.
Installation
1. Clean cylinder head face and inlet/exhaust manifold faces. Use and air line to completely dry cylinder head
surfaces.
2. Lubricate and install intake and exhaust valves (x32).
3. Install valve stem oil seals.
4. Install valve springs and collars.
5. Using valve spring compressor, compress valve spring, install collets.
6. Release/remove spring compressor.
7. Install selective tappet buckets in their original fitted positions.
8. Lubricate intake and exhaust camshaft bearings and journals with clean engine oil.
9. Install intake and exhaust camshafts, install bearing caps (x20), install bolts (x40).
10. Torque tighten bearing cap bolts in the correct sequence.
11. Install camshaft sprocket Torx bolts in intake and exhaust camshafts.
12. Rotate intake camshaft clockwise, check and log each valve clearance using feeler gauges.
13. Calculate the correct tappet bucket grade.
14. Remove bearing cap bolts (x40), remove bearing caps (x20), remove intake and exhaust camshafts.
15. Remove tappet buckets, install selected tappet buckets.
16. Install intake and exhaust camshafts, install bearing caps (x20), install bolts (x40).
17. Torque tighten bearing cap bolts in the correct sequence.
18. Rotate intake and exhaust camshafts clockwise, re- check each valve clearance using feeler gauges.
19. Remove camshaft sprock et Torx bolts (x4).
Repair Operation Time (ROT)

Engine Structure (03.01)
3-1-16Workshop ManualIssue 4, November 2008
20. Remove bearing cap bolts (x40), remove bearing caps
(x20), remove intake and exhaust camshafts.
21. Install spark plugs.
22. Install cylinder head gaskets - engine set (see Workshop Manual procedure 03.10.AL Gasket - Cylinder Head -
Engine Set - Renew).
Inlet Valve (Set) - Renew
Removal
1. Remove cylinder head gaskets - engine set (see Workshop Manual procedure 03.10.AL Gasket -
Cylinder Head - Engine Set - Renew).
2. Remove spark plugs from cylinder head.
3. Remove intake selective tappet buckets from cylinder heads, keep in their fitted order.
4. Position valve spring compressor, compress valve springs (see Figure 1).
Figure 1
5. Remove collets (x2), releas e/remove spring compressor,
collect collar and valve spring.
6. Remove intake valves from cylinder heads.
7. Remove valve stem oil seas.
8. Keep intake valves and springs in their fitted order.
9. Inspect condition and measure free length of valve springs.
10. Use new valves and check valve guide clearance.
Installation
1. Clean cylinder head face and inlet/exhaust manifold faces. Use and air line to completely dry cylinder head
surfaces.
2. Lubricate and install intake valves (x16).
3. Install valve stem oil seals.
4. Install valve springs and collars. 5. Using valve spring compressor, compress valve spring,
install collets.
6. Release/remove spring compressor.
7. Install intake selective tappet buckets in their original fitted positions.
8. Lubricate intake camshaft bearings and journals with clean engine oil.
9. Install intake camshafts, inst all bearing caps (x10), install
bolts (x20).
10. Torque tighten bearing cap bolts (x20) in the correct sequence.
11. Install camshaft sprocket Torx bolts in each intake
camshaft.
12. Rotate each intake camshaft clockwise, check and log each valve clearance using feeler gauges.
13. Calculate the correct tappet bucket grade.
14. Remove bearing cap bolts (x20), remove bearing caps (x10), remove both intake camshafts.
15. Remove tappet buckets, install selected tappet buckets.
16. Install both intake camshaf ts, install bearing caps (x10),
install bolts (x20).
17. Torque tighten bearing cap bolts in the correct sequence.
18. Rotate intake camshafts clockwise, re-check each valve clearance using feeler gauges.
19. Remove intake camshaft sp rocket Torx bolts (x2).
20. Remove bearing cap bolts (x20), remove bearing caps (x10), remove both intake camshafts.
21. Install spark plugs.
22. Install cylinder head gaskets - engine set (see Workshop Manual procedure 03.10.AL Gasket - Cylinder Head -
Engine Set - Renew).
Exhaust Valve (Set) - Renew
Removal
1. Remove cylinder head gaskets - engine set (see Workshop Manual procedure 03.10.AL Gasket -
Cylinder Head - Engine Set - Renew).
2. Remove spark plugs from cylinder head.
3. Remove exhaust selective tappet buckets from cylinder heads, keep in their fitted order.
Repair Operation Time (ROT)
A0301310
Repair Operation Time (ROT)
ItemCode
Exhaust Valve (Set)-Renew LHD03.01.HC
Exhaust Valve (Set)-Renew RHD03.01.JC