charging 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

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

3-0-2 Workshop Manual Issue 5, January 2010
Drive Belt-Renew ...................................................5-1
Engine Drive Belt and Bracket Assembly Oil Pump
Tensioner-Renew ...................................................5-1
Idler Pulley-Renew .................................................5-2
Engine Drive Belt Idler Assembly-Renew ................5-2
Engine Cranking System (03.06) ........................... 3-6-1 Maintenance ...........................................................6-1 Starter Motor-Renew ..............................................6-1
Ignition System (03.07) ......................................... 3-7-1 Maintenance ...........................................................7-1 Coil Assembly-Engine Set - LH-Renew ....................7-1
Emission Control (03.08) ...................................... 3-8-1 Maintenance ...........................................................8-1 Vacuum Outlet Hose Assemb ly-Renew ..................8-1
Secondary Air Injection Pump Tube-Renew............8-1
Vacuum System Reservoir and Bracket Assembly
- Renew .................................................................8-1
Oil Tank Breather Hose-Renew ..............................8-1
Air Cleaner to Rocker Cover Hose-Renew ..............8-1
Oil Separator Tube Assembly-Renew ......................8-1
Oil Separator Assembly-Renew...............................8-2
Emissions Separator Hose-Renew ...........................8-2
Secondary Air Injection Pump and Bracket
Assembly-Renew ....................................................8-2
PCV Valve Assembly-Renew ...................................8-2
Crank Vent Hose-Renew ........................................8-3
Exhaust Valve to Exhaust Manifold Tube Assembly
- Renew .................................................................8-3
Oil Separator to Inlet Manifold Hose- Renew .........8-3
EGR Module-Renew...............................................8-3
Valve Train (03.09)................................................ 3-9-1 Specifications ..........................................................9-1
Maintenance ...........................................................9-1 Left Side Timing Chain Arm Assembly - Remove
and Install ..............................................................9-1
Right Side Timing Chain Arm Assembly - Remove
and Install ..............................................................9-8
RH/LH Secondary Tensioner Assembly - Remove
and Install ............................................................9-14
Right and Left Intake Camshaft - Remove
and Install ............................................................9-15
Right and Left Exhaust Camshaft - Remove
and Install ............................................................9-17
RH/LH Secondary Timing Chain-Renew ...............9-18
RH/LH Secondary Tensioner Assembly-Renew
(with Engine Removed).........................................9-19
RH/LH Intake Camshaft Renew With Engine
Removed .............................................................9-20
RH/LH Exhaust Camshaft-Renew (with Engine
Removed) ............................................................9-22
RH/LH Secondary Timing Chain-Renew (with
Engine Removed) .................................................9-24
RH/LH Intake Camshaft Sprocket and Housing Assembly-
Renew......................................................................9-25 Left Side Primary Chain - Re move and Install).......9-26
RH/LH Intake Camshaft Sprocket and Housing
Assembly-Renew (with Engine Removed) .............9-29
Engine Sealing (03.10) ........................................ 3-10-1 Specifications ........................................................10-1 Maintenance ......................................................... 10-1
Engine Timing Cover - Renew .............................. 10-1
Left Side Cam Cover - Remove and Install ............ 10-4
Left Side Cam Cover Gasket - Renew ................... 10-5
Right Side Cam Cover Gasket - Renew ................. 10-6
Cylinder Head Gasket - Renew (Engine Set) ......... 10-6
Right Side Cam Cover - Remove and Install .......... 10-9
Cam Cover - Vehicle Set - Remove and Install .... 10-10
Engine Timing Cover- Renew (with Engine
Removed) .......................................................... 10-11
John Guest Cartridge in the Engine Timing Cover
- Repair .............................................................. 10-14
Power Conversion (03.11) ...................................3-11-1 Maintenance ......................................................... 11-1 Connecting Rod Bearing-Renew (Engine Set) ........ 11-1
Crankshaft Main Bearing-Renew (Engine Set)........ 11-1
Crankshaft Assembly-Renew................................. 11-4
Piston-Renew (Engine Set) .................................... 11-7
Piston-Renew ..................................................... 11-12
Additional Piston-Renew (E ach) .......................... 11-17
Piston Ring-Renew (Engine Set) .......................... 11-18
Piston Ring-One Piston Se t-Renew ..................... 11-23
Piston Ring Set-Additional -Renew (Each) ............ 11-28
Connecting Rod-Renew (Engin e Set) .................. 11-29
Crankshaft Damper Pulley Assembly-Renew ....... 11-34
Crankshaft Front Oil Seal-R enew ........................ 11-35
Rear Oil Crankshaft Seal-Renew ......................... 11-36
Cylinder Block-Renew........................................ 11-36
Crankshaft Damper Pulley Assembly-Renew
(with Engine Removed) ...................................... 11-37
Crankshaft Front Oil Seal-Renew (with
Engine Removed) ............................................... 11-37
Crankshaft Rear Oil Seal-Renew (with
Engine Removed) ............................................... 11-38
Air Charging (03.12) .......... ..................................3-12-1
Maintenance ......................................................... 12-1 Clean Air Duct - Remove and Install ..................... 12-1
Engine Air Filter - Remove and Install ................... 12-1
Engine Air Cleaner Assembly - Remove
and Install ............................................................ 12-2
Evaporative Emissions (03.13 ) .............................3-13-1
Description ........................................................... 13-1 System Operation ................................................ 13-1
Engine Management System (03.14) ...................3-14-1 Maintenance ......................................................... 14-1 Right Engine Control Module - Renew.................. 14-1
LH Front Lower Heated Exhaust Gas Oxygen
(HEGO) Sensor - Renew....................................... 14-1
LH Front Upper Heated Exhaust Gas Oxygen
(HEGO) Sensor - Renew....................................... 14-1
RH Front Upper Heated Exhaust Gas Oxygen
(HEGO) Sensor - Renew....................................... 14-2
RH Rear Lower Heated Exhaust Gas Oxygen
(HEGO) Sensor - Renew....................................... 14-2
Left Side Powertrain Control Module (PCM)
(Coupe Only) - Remove and Install....................... 14-3
Left Side Powertrain Control Module (PCM)
(Roadster Only) - Remove and Install.................... 14-4

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)

Fuel Charging System (03.04)
Engine (03.00)3-4-6 Workshop Manual May 2007
Installation
1. Install new O-rings to remaining injectors (lube O-ringP-
clips).
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 EGR vac pipe to sensor and manifold.
5. Install coolant pipe bracket (bolt x2, nut x2).
6. Connect EGR (x1), fuel rail pressure sensor (x1) and injector multiplugs (x4).
7. Refit harness to coolant pipe bracket (fir tree x3).
8. Connect heater hose to pipe (quick fit).
9. Refit heater hose (clipx2) and EGR vacuum lines (clips
x2) to bracket.
10. Install fuel feed pipe.
11. Install purge pipe P-clip.
12. Install harness bracket to engine.
13. Feed harness into inner wing area.
14. Install fusebox to bracket.
15. Install earth lead to fusebox.
16. Install battery lead to fusebox (1x nut and rubber cover).
17. Install multiplugs to fuse box.
18. Install fusebox bracket fixings.
19. Refit harness fir tree clips to cylinder head.
20. Refit engine breather hose.
21. Install VVT solenoid multiplug, position coil and CMP harness (1x edge clip).
22. Install ECM (see Workshop Manual procedure 03.14.BB Engine Control Module - RH Renew).
Engine Set - Fuel Injector - 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 clips.
15. Remove fuel rail bolts (x2) and lift rail (tie aside).
16. 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 breather hose to manifold (quickfit).
4. Connect IAT multiplug.
5. Unclip injector harness from cam cover (x2).
6. Connect injector multiplugs (x4).
7. Install pipe support bracket (nuts x2, bolts x2).
8. Install harness support bracket (bolt x1, nut x2) release harness clips (fir tree x3).
9. Connect booster hose to manifold and support clip.
10. Connect heater hose from pipe (quick fit).
11. Install heater hose (x2) and throttle body hose (x2) from support bracket.
12. Connect purge line to manifold and into support clip.
13. Connect breather hoses (x2) to cam cover.
14. Install corner cross brace (torque bolts with vehicle on level ground).
Engine Set - Fuel Injector - 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 fixings (bolt and nut) (allows movement).
5. Remove ECM (see Workshop Manual procedure 03.14.BB Engine Contro l Module - RH Renew).
6. Remove battery lead (1x nut and rubber cover) from fuse box (2x leads).
7. Remove multiplugs (x10) from fusebox.
Repair Operation Time (ROT)
Repair Operation Time (ROT)
ItemCode
Engine Set-Fuel Injector-RH Bank-
Renew LHD
03.04.GK
Engine Set-Fuel Injector-RH Bank-
Renew RHD
03.04.GP

Fuel Charging System (03.04)
Engine (03.00)
May 2007 Workshop Manual 3-4-7
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 coolant pipe bracket (fir tree x3).
18. Disconnect EGR (x1), fuel ra il pressure sensor (x1) and
injector multiplugs (x 4), 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 clips.
22. Remove fuel rail bolts (x2) and lift rail (tie aside).
23. 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.
17. Install fusebox bracket fixings.
18. Refit harness fir tree clips to cylinder head.
19. Refit engine breather hose.
20. Install VVT solenoid multip lug, position coil and CMP
harness (1x edge clip).
21. Install ECM (see Workshop Manual procedure 03.14.BB Engine Control Module - RH Renew).