check engine ASTON MARTIN V8 VANTAGE 2010 Workshop Manual

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.

Vehicle Identification Number
Issue 5, January 2010 Workshop Manual 0-0-11
Vehicle Identification Number
The Vehicle Identification Number (VIN) is a 17 character number which uniquely identifies the vehicle and gives
fundamental data on the build site, date and initial configuration of the vehicle.
VIN Number Location
The VIN number is shown on two labels in the vehicle:
1 Under the lower edge of the windscreen.
2 Front of the engine bay. • The VIN number is also stamped into the floorpan in
the right-hand front footwell (under the carpet through
the foam slot).
S CFBC3A45GC00001
Code for AML
Restraint System
Transmission and Steering
Body Type
Engine Type
Calculated Check Digit
Model Year
Manufacturing Plant
Series Identifier
Sequential Chassis Number

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

Engine Assembly (03.00)
Engine (03.00)
Issue 5, January 2010 Workshop Manual 3-0-15
49. Connect multiplugs (x3) RH side of engine bay (refer to Figure 40).
Purge Install
50. Connect purge pipe to purge valve.
51. Install bottom screws (x2) and tighten top screw of washer bottle.
52. Move pipe into position and install pipe to support clips (x2).
Fuel Install
53. Install fuel hose to rail (clip x1).
Clutch Pipe Install
54. Install clutch metal pipe from flexible.
55. Install flexible hose grommet to support bracket.
56. Bleed clutch.
Suspension Install
57. Install front springs and dampers. (refer to Workshop Manual procedure 04.03.AA Spring and Damper
Assembly - Front Pair - Renew).
58. Install RH wheel arch liner (refer to Workshop Manual procedure 01.02.GB Wheel Arch Liner - Front - RH -
Renew
59. Install LH wheel arch liner (refer to Workshop Manual procedure 01.02.FB Wheel Arch Liner - Front - LH -
Renew).
60. Install bottom arms (nut and bolt x4) with uprights and top arm.
61. Install level sens or link to bottom arm (nut x1).
62. Connect level sensor multiplug.
63. Connect track rod ends (nut x2).
64. Install anti-roll bar to links (nuts x2).
65. Install brake discs.
66. Install brake callipers.
67. Install road wheel/s Throttle Duct Install
68. Connect breather pipe quic
kfits (x2) from air cleaner
duct (refer to Figure 41).
69. Install throttle body duct (refer to Figure 42).
General Install
70. Remove strap - vehicle to ramp (front).
71. Lower vehicle on ramp.
72. Connect vehicle battery.
73. Top-up PAS fluid.
74. 4 wheel alignment check/adjust (refer to Workshop Manual procedure 04.00.AD 4 Wheel Alignment -
Check and Adjust).
75. Install transmission (refer to Workshop Manual procedure 07.03.AA Transaxle Assembly - Manual -
Remove for Access and Refit).
76. Use handbook procedure to check oil level.
Figure 40
$3#
Figure 41
Figure 42
$3#
$3#

Engine Structure (03.01)
Issue 4, November 2008Workshop Manual 3-1-13
13. Remove bolts (x10), evenly and in stages securing RH
cylinder head to cylinder block (see Figure 3).
Figure 3
14. With assistance, remove RH cylinder head assembly.
15. Remove and discard cylinder head gasket.
Installation
1. Thoroughly clean RH cylind er head face and retaining
bolt pockets.
2. Thoroughly clean RH cylinder block face.
3. Thoroughly clean and dry RH cylinder head retaining
bolts.
4. Install new RH cylinder gasket, locate on dowels.
5. With assistance, install RH cylinder head, locate on dowels.
6. Install and torque tighten cylinder head bolts (x12) in the correct sequence.
7. Lubricate RH exhaust camsha ft journals, camshaft lobes,
bearing surfaces on cylinder head and bearing caps with
clean engine oil.
8. Install RH exhaust camshaft, install bearing caps (x5) in their original positions.
9. Install bolts (x10) and torque tighten in the sequence specified.
10. Install sprocket retaining Torx bolt in camshaft.
11. Rotate camshaft accordingly and check each valve clearance using feeler gauges.
12. Remove sprocket retaining Torx bolt.
13. Install RH/LH intake cams haft (see Workshop Manual
procedure 03.09.AT/03.09.AV Camshaft - Intake - RH/
LH - Renew).
14. Install timing chain tensioni ng tool (303-532) into RH
exhaust camshaft sprocket.
15. Apply a force to the tool (303-532) in an anti-clockwise direction and torque tighten RH sprocket Torx bolts.
Remove special tool.
16. Connect multiplug to cam a haft timing sensor.
17. Connect multiplugs (x2) to knock sensors.
18. Install SAI pump and bracket assembly (see Workshop Manual procedure 03.08.DB/03.08.DJ Pump and
Bracket Assembly - Secondary Air Injection - Renew). 19. Install RH/LH exhaust manifold (see Workshop Manual
procedure 09.00.CC/09.00.CD Gasket - Exhaust
Manifold - RH/LH - Renew).
20. With assistance, position engine support beam (SPX M553D) and secure to engine.
21. Position trolley, support front subframe, remove bolts (x6), raise vehicle, remove trolley.
22. Install and torque tighten engine mounting nuts (x2).
RH/LH Cylinder Head - Overhaul
1. Remove cylinder head gasket - RH (see Workshop Manual procedure 03.01.GU Gasket - Cylinder Head -
RH - Renew).
2. Remove Torx screws (x2) se curing EGR tube to cylinder
head, remove tube.
3. Remove and discard gasket.
4. Remove bolt securing camshaf t timing sensor to cylinder
head, remove sensor.
5. Remove bolts (x2) securing knock sensors (x2) to cylinder head, remove sensors.
6. Remove spark plugs from cylinder head.
7. Remove selective tappet buckets, keep in their fitted order.
8. Position valve spring compressor, compress valve spring (see Figure 1).
Figure 1
9. Remove collets (x2), releas e/remove spring compressor,
collect collar and valve spring.
10. Remove valve from cylinder.
11. Remove valve stem oil seal.
12. Repeat procedure for remaining valve assemblies.
13. Keep valves and springs in their fitted order.
A0310319
Repair Operation Time (ROT)
A0301310

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

Engine Structure (03.01)
Issue 4, November 2008Workshop Manual 3-1-17
4. Position valve spring compressor, compress valve springs
(see Figure 1).
Figure 1
5. Remove collets (x2), release/remove spring compressor, collect collar and valve spring.
6. Remove exhaust valves from cylinder heads.
7. Remove valve stem oil seas.
8. Keep exhaust 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 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 exhaust selective tappet buckets in their original fitted positions.
8. Lubricate exhaust camshaft be arings and journals with
clean engine oil.
9. Install exhaust camshafts, install 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 exhaust camshaft.
12. Rotate each exhaust camshaf t 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 exhaust camshafts.
15. Remove tappet buckets, install selected tappet buckets. 16. Install both exhaust camshaft
s, install bearing caps (x10),
install bolts (x20).
17. Torque tighten bearing cap bolts in the correct sequence.
18. Rotate exhaust camshafts clockwise, re-check each valve clearance using feeler gauges.
19. Remove exhaust camshaft sprocket Torx bolts (x2).
20. Remove bearing cap bolts (x20), remove bearing caps (x10), remove both 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).
Spring (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 heads (x8).
3. Remove selective tappet buckets, keep in their fitted order.
4. Position valve spring compressor, compress valve springs (see Figure 1).
Figure 1
5. Remove collets, release/remove spring compressor, collect collars and valve springs.
6. Inspect cylinder head face for warpage, across centre and from corner to corner.
Installation
1. Clean cylinder head face and inlet/exhaust manifold faces. Use and air line to completely dry cylinder head
surfaces.
2. Install valve springs and collars.
A0301310
Repair Operation Time (ROT)
A0301310

Engine Structure (03.01)
3-1-18Workshop ManualIssue 4, November 2008
3. Using valve spring compressor, compress valve spring,
install collets.
4. Release/remove spring compressor.
5. Install selective tappet buckets in their original fitted positions.
6. Lubricate intake and exhaust camshaft bearings and journals with clean engine oil.
7. Install intake and exhaust camshafts, install bearing caps (x20), install bolts (x40).
8. Torque tighten bearing cap bolts in the correct sequence.
9. Install camshaft sprocket Torx bolts in intake and exhaust camshafts.
10. Rotate intake camshaft clockwise, check and log each valve clearance using feeler gauges.
11. Calculate the correct tappet bucket grade.
12. Remove bearing cap bolts (x40), remove bearing caps (x20), remove intake and exhaust camshafts.
13. Remove tappet buckets, install selected tappet buckets.
14. Install intake and exhaust camshafts, install bearing caps (x20), install bolts (x40).
15. Torque tighten bearing cap bolts in the correct sequence.
16. Rotate intake and exhaust camshafts clockwise, re- check each valve clearance using feeler gauges.
17. Remove camshaft sprocket Torx bolts (x4).
18. Remove bearing cap bolts (x40), remove bearing caps (x20), remove intake and exhaust camshafts.
19. Install spark plugs.
20. Install cylinder head gaskets - engine set (see Workshop Manual procedure 03.10.AL Gasket - Cylinder Head -
Engine Set - Renew).
Spring (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 heads (x8).
3. Remove intake selective tappet buckets, keep in their fitted order. 4. Position valve spring compressor, compress valve springs
(see Figure).
Figure 1
5. Remove collets, release/remove spring compressor, collect collars and valve springs.
6. Inspect cylinder head face for warpage, across centre and from corner to corner.
Installation
1. Clean cylinder head face and inlet/exhaust manifold faces. Use and air line to completely dry cylinder head
surfaces.
2. Install intake valve springs and collars.
3. Using valve spring compressor, compress valve spring, install collets.
4. Release/remove spring compressor.
5. Install intake selective tappet buckets in their original fitted positions.
6. Lubricate both intake camsh aft bearings and journals
with clean engine oil.
7. Install both intake camshafts, install bearing caps (x10), install bolts (x20).
8. Torque tighten bearing cap bolts in the correct sequence.
9. Install camshaft sprocket Torx bolts in both intake camshafts.
10. Rotate intake camshafts clockwise, check and log each valve clearance using feeler gauges.
11. Calculate the correct tappet bucket grade.
12. Remove bearing cap bolts (x20), remove bearing caps (x10), remove both intake camshafts.
13. Remove tappet buckets, install selected tappet buckets.
14. Install intake camshafts, inst all bearing caps (x10), install
bolts (x20).
15. Torque tighten bearing cap bolts in the correct sequence.
16. Rotate both intake camshafts clockwise, re-check each valve clearance using feeler gauges.
17. Remove camshaft sprocket Torx bolts (x4).
Repair Operation Time (ROT)
A0301310