fill engine oil ASTON MARTIN V8 VANTAGE 2010 Workshop Manual

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 Assembly (03.00)
Engine (03.00)
Issue 5, January 2010 Workshop Manual 3-0-11
9. Connect bottom hose (refer to Figure 22).
10. Connect expansion tank to engine hose.
11. Connect heater feed hose (quickfit) (refer to Figure 23).
12. Connect heater return hose (quickfit).
13. Connect expansion tank to engine (bleed) hose and body clips (x2).
14. Refill coolant (refer to Workshop Manual procedure 03.03.AD Coolant - Drain and Refill).
Booster Hose Install
15. Install vacuum hose to booster.
P.A.S. Install
16. Connect H.P. pipe to pump (renew O-ring).
17. Install PAS reservoir to bracket (bolt x1). 18. Install hoses (x2) to PAS reservoir (refer to Figure 24).
19. Install suction hose to body P-clip (bolt x1).
20. Install pipes to steering rack
(bolt x1) and fit new O-rings
(x2).
Oil Tank Install
21. Connect oil pipe from oil thermostat.
22. Install oil tank (bolts x4) (refer to Figure 25).
Figure 22
Figure 23
$3#
$3#
Figure 24
Figure 25
$3#
$3#

Engine Assembly (03.00)
Engine (03.00)3-0-12 Workshop Manual Issue 5, January 2010
23. Connect breather hose to tank (quickfit) (refer to Figure
26).
24. Connect oil pipes to tank (x3) (refer to Figure 27).
25. Fill tank with approximatel y amount of displaced oil and
replace cap.
A/C Install
26. Fit new O-rings to A/C pipes (lubricate). 27. Install pipes to compressor (b
olts x2) (refer to Figure 28).
28. Install bolt (x1) HP pipe to bracket (refer to Figure 29).
29. Install bolts (x2) LP pipe to body P-clips (refer to Figure 30).
30. Connect compressor clutch multiplug.
Figure 26
Figure 27
$3#!
$3#
Figure 28
Figure 29
Figure30
$3#
$3#
$3#

Engine Structure (03.01)
Issue 4, November 2008Workshop Manual 3-1-5
Maintenance
Upper Intake Manifold Assembly (LHD) -
Renew
Removal
1. Depressurise fuel rail (see Workshop Manual procedure
10.01.EK Fuel System - Depressurise).
2. Coolant drain (see Workshop Manual procedure 03.03.AD Coolant - Drain and Refill).
3. Remove cross brace (bolts x4).
Removal 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 Contro l Module - RH - Renew).
9. Remove battery lead (1x nut and rubber cover) from fuse box (2x leads).
10. Remove multiplugs (x10) from fusebox.
11. Remove earth terminal (x1 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.
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 ra il pressure sensor (x1) and
injector (x4) multiplu gs, move harness aside. 22. Remove coolant pipe bracket (nuts x2 and bolts x2).
23. Disconnect EGR vacuum 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 quickfits (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) (see Figure 1).
Figure 1
44. Remove bolts (x2) bracket to manifold (rear).
45. Move manifold (2x people) forward, remove bolt for purge line P-clip, remove manifold.
46. Remove gaskets and clean mating faces.
EGR pipe and exhaust manifold
flanges.
25 18
Camshaft position (CMP) sensor 7 5
Torque Figures
DescriptionNm.lb/ft
Clearance Figures
Exhaust valve0.23mm - 0.27mm
Inlet Valve clearance 0.18mm - 0.22mm
Repair Operation Time (ROT)
A030113

Engine Structure (03.01)
3-1-6Workshop ManualIssue 4, November 2008
Removal Manifold Parts
47. Remove EGR valve (bolts x2) and gasket.
48. Remove IAT sensor.
49. Remove throttle body (bolts x4) and gasket.
50. Remove fuel rail (bolts x4) with injectors.
Installation
1. Install fuel rail (bolts x4) with injectors. (fit new O-rings
to injectors).
2. Install throttle body (bolts x4) and new gasket.
3. Install IAT sensor.
4. Install EGR valve and new gasket.
Installation Manifold to Vehicle
5. Install new gaskets to cylinder block (glue in place).
6. Install manifold (allowing access to install bolt for purge line P-clip).
7. Install manifold bolts (x 10) (torque and tightening
sequence).
8. Install bolts (x2) bracket to manifold (rear).
9. Connect EGR pipe union.
10. Connect EGR vacuum hose.
11. Connect air cleaner duct (clip x1).
12. Connect breather pipe quickf its (x2) to air cleaner duct.
13. Connect throttle body multiplug and harness clip.
14. Connect manifold heating hoses (x2).
Installation RH Side
15. Connect EGR vacuum pipe to sensor and manifold.
16. Install coolant pipe bracket (bolt x2, nut x2).
17. Connect EGR (x1), fuel rail pressure sensor (x1) and injector multiplugs (x4).
18. Refit harness to coolant pipe bracket (fir tree x3).
19. Connect heater hose to pipe (quick fit).
20. Refit heater hose (clipx2) and EGR vacuum lines (clips
x2) to bracket.
21. Install fuel feed pipe.
22. Install purge pipe P-clip.
23. Install harness bracket to engine.
24. Feed harness into inner wing area.
25. Install fusebox to bracket.
26. Install earth lead to fusebox.
27. Install battery lead to fusebox (1x nut and rubber cover).
28. Install multiplugs to fuse box.
29. Install fusebox bracket fixings.
30. Refit harness fir tree clips to cylinder head.
31. Refit engine breather hose.
32. Install VVT solenoid multiplug, position coil and CMP harness (1x edge clip).
33. Install ECM (see Workshop Manual procedure 03.14.BB Engine Control Module - RH - Renew).
34. Install coil cover.
Installation LH Side
35. Connect breather hose to manifold (quickfit). 36. Connect IAT multiplug.
37. Unclip injector harness from cam cover (x2).
38. Connect injector multiplugs (x4).
39. Install pipe support bracket (nuts x2, bolts x2).
40. Install harness support bracket (bolt x1, nut x2) release
harness clips (fir tree x3).
41. Connect booster hose to manifold and support clip.
42. Connect heater hose from pipe (quick fit).
43. Install heater hose (x2) and throttle body hose (x2) from support bracket.
44. Connect purge line to manifold and into support clip.
45. Connect breather hoses (x2) to cam cover.
46. Install coil cover.
47. Install corner cross brace (torque bolts with vehicle on level ground).
48. Refill coolant (see Workshop Manual procedure 03.03.AD Coolant - Drain and Refill).
49. Install cross brace. (torque bolts with vehicle on level
ground).
Upper Intake Manifold Assembly (RHD)
- Renew
Removal
1. Depressurise fuel rail (see Workshop Manual procedure 10.01.EK Fuel System - Depressurise).
2. Coolant drain (see Workshop Manual procedure 03.03.AD Coolant - Drain and Refill).
3. Remove cross brace (bolts x4).
Removal RH Side
4. Remove coil cover.
5. Remove corner cross brace.
6. Disconnect breather hose (quick fit) move aside.
7. Remove purge pipe P-clip (bolt x1) and move pipe
aside.
8. Remove harness bracket from engine (bolts x2, nut x1).
9. Release fuel feed hose from rail (clip x1) and move aside.
10. Disconnect heater hose from pipe (quick fit).
11. Release heater hose (clips x2) and EGR vacuum line (clips x2) from bracket.
12. Release harness from coolant pipe bracket (fir tree x3).
13. Disconnect EGR (x1), fuel rail pressure sensor (x1) and injector (x4) multiplugs, move harness aside.
14. Remove coolant pipe bracke t (nuts x2 and bolts x2).
15. Disconnect EGR vacuum pipe from sensor and
manifold, move aside. Note: The installation is not handed
Repair Operation Time (ROT)
ItemCode
Upper Intake Manifold Assembly-
Renew RHD
03.01.BE

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

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

Engine Structure (03.01)
Issue 4, November 2008Workshop Manual 3-1-11
23. Install VVT solenoid multiplug, position coil and CMP
harness (1x edge clip).
24. Install corner cross brace (t orque bolts with vehicle on
level ground).
25. Install coil cover.
Installation LH Side
26. Connect breather hose to manifold (quickfit).
27. Connect IAT multiplug.
28. Install injector harness to cam cover (x2).
29. Connect injector multiplugs (x4).
30. Install pipe support bracket (nuts x2, bolts x2).
31. Install harness support bracket (bolt x1, nut x2) release harness clips (fir tree x3).
32. Connect booster hose to manifold and support clip.
33. Connect heater hose from pipe (quick fit).
34. Install heater hose (x2) and throttle body hose (x2) from support bracket.
35. Connect purge line to mani fold and into support clip.
36. Connect breather hoses (x2) to cam cover.
37. Feed harness into inner wing area.
38. Install fusebox to bracket.
39. Install earth lead to fusebox.
40. Install battery lead to fusebox (1x nut and rubber cover).
41. Install multiplugs to fuse box.
42. Install fusebox bracket fixings.
43. Install ECM (see Workshop Manual procedure 03.13.ND Module - Powe r Train Control - RHD -
Renew)
44. Install coil cover.
45. Refill coolant (see Workshop Manual procedure 03.03.AD Coolant - Drain and Refill).
46. Install cross brace. (torque bolts with vehicle on level
ground).
Intake Manifold Assembly - Remove for
Access and Refit (With Engine Removed
)
Removal
1. Remove RH coil cover.
2. Disconnect breather hose (quick fit).
3. Release alternator and injector harness fir tree clips (x3) from cylinder head.
4. Remove nut and bolts (x2) securing harness bracket to
engine, remove bracket.
5. Release heater hose (clips x2) and EGR vacuum line (clips x2) from bracket.
6. Release alternator and injector harness fir tree clips (x3) from coolant pipe bracket. 7. Disconnect multiplugs from EGR valve, fuel rail pressure
sensor and injectors (x4).
8. Remove nuts (x2) and bolts (x2) securing coolant pipe
bracket, remove bracket.
9. Disconnect EGR vacuum pipe from sensor and manifold.
10. Remove LH coil cover.
11. Disconnect breather hoses (x2) from LH engine cover.
12. Disconnect purge line from manifold (quickfit) and
support clip for access.
13. Disconnect heater hose from pipe (quick fit).
14. Release heater hose (x2) and throttle body hose (x2) from support bracket.
15. Remove bolt and nuts (x2) securing harness support bracket, release harness clips (fir tree x3). Remove
bracket.
16. Remove nuts (x2) and bolts (x2) pipe support bracket.
17. Disconnect injector multiplugs (x4).
18. Release injector harness clip s (x2) from LH engine cover.
19. Disconnect IAT multiplug.
20. Disconnect breather hose from manifold (quickfit).
21. Disconnect manifold heating hoses (x2).
22. Disconnect throttle body multiplug and harness clip.
23. Disconnect EGR vacuum hose.
24. Loosen and disconnect EGR pipe union from EGR valve.
25. Remove bolts (x2) securing EGR pipe to RH exhaust
manifold, remove pi pe, discard gasket.
26. Progressively loosen and remove bolts (x 10) securing intake manifold to cylinder heads (see Figure 1).
Figure 1
27. Carefully remove intake ma nifold from cylinder heads.
28. Remove and discard gaskets (x2).
Installation
1. Clean intake manifold and mating faces on cylinder heads.
2. Install new gaskets to cyli nder block (glue in place).
3. Install intake manifold (allowing access to install bolt for purge line P-clip).
4. Install and torque tighten in take manifold bolts (x10) in
the correct sequence.
5. Clean EGR pipe and mating face on exhaust manifold.
Repair Operation Time (ROT)
A030113

Lubrication System (03.02)
Engine (03.00)3-2-2 Workshop Manual Issue 5, Janauary 2010
Specifications
Engine Oil Specification
Maintenance
Oil Pressure Pump to Sump Gasket -
Renew
1. Remove crankshaft timing chain sprocket (refer to Workshop Manual procedure 03.09.AK Sprocket -
Crankshaft - Renew).
2. Install guide pin through lower hole on chain tensioner. 3. Remove bolt that attaches
the oil pressure pump chain
tensioner assembly to engine bedplate (refer to Figure
1).
4. Remove tensioner assembly.
5. Remove bolts (x3) that attach the oil pressure pump to sump.
6. Release chain from oil pres sure pump sprocket, remove
oil pump.
7. Remove and discard oil pressure pump gasket.
Installation
1. Clean oil pressure pump and mating face on sump.
2. Install new gasket to sump, align to dowels (x2).
3. Position oil pressure pump, install chain on pump sprocket.
4. Install oil pressure pump, align to dowels (x2), Install and torque tighten bolts (x3).
5. Install chain tensioner, install and torque tighten bolt, remove guide pin.
6. Install crankshaft timing chain sprocket (refer to Workshop Manual procedure 03.09.AK Sprocket -
Crankshaft - Renew).
Oil Pump Chain - Renew
Removal
1. Remove oil pressure pump gasket (refer to Workshop Manual procedure 03.02.AG Gasket - Oil Pressure
Pump to Sump - Renew)
Engine oil
Europe/Aus/USA Castrol Edge Sport 10W-60
To achieve the required high performance of synthetic
lubricants, do not mi x with mineral oils.
Capacity Europe (Litres)UK
(Pints)USA
(Qts.)
Full System 13 23 11
Service Fill 10 18 9
Torque Figures
DescriptionNmlb/ft
Oil filter 15 - 18 11-13
Sump plug 20 - 26 15-19
Sump bolts 20 - 22 15-16
Oil delivery pump bolts 19 - 23 14-17
Oil scavenger pump bolts 19 - 23 14-17
Oil scavenger filters 11 - 13 8-10
Oil temperature sensor 16 - 24 12-17
Oil pressure switch 11 - 15 8-11
Oil pump tensioner bracket 11 - 13 8-10
10W-60
AuthorityStandard
API SL/CF
ACEA A3/B3/B4
Oil 10W-60 has both API and ACEA and therefore meets
more demanding tests than eith er API or ACEA oils alone.
Repair Operation Time (ROT)
Figure 1
Repair Operation Time (ROT)
ItemCode
Oil Pump Chain-Renew 03.02.AJ
A0302274

Lubrication System (03.02)
Engine (03.00)
Issue 5, Janauary 2010 Workshop Manual 3-2-9
6. Fill tank with approximately amount of displaced oil and replace cap.
7. Use handbook procedure to check oil level.
Oil Cooler Tank Assembly - Renew
Removal
1. Disconnect breather pipe qu ickfits (x2) from air cleaner
duct.
2. Remove throttle body du ct for access (clips x3).
3. Remove cap.
4. Disconnect top hose from engine (clip x1) tie aside
(catch coolant).
5. Remove breather pipe from oil tank (quick fit) (refer to Figure 1).
Figure 1
6. Remove pipes (x2) fr om oil tank, tie aside.
7. Raise vehicle on ramp.
8. Remove undertray (refer to Workshop Manual procedure 01.02.NB Undertray - Front - Renew).
9. Drain oil tank. 10. Remove bottom pipe (x1) from oil tank (refer to Figure
2).
Figure 2
11. Remove bolts (x3) that attach the oil thermostat to body (allows oil hose movement).
12. Lower ramp.
13. Remove bolts (x4) that attach the tank to body and lift out.
Installation
1. Position tank to body and fit bolts (x4) (torque).
2. Install oil pipes to tank (torque).
3. Connect breather hose.
4. Connect top hose to engine (clip x1).
5. Raise vehicle on ramp.
6. Install bottom oil pipe to tank (torque).
7. Install bolts (x3) that attach the oil thermostat to body (torque).
8. Install undertray (refer to Workshop Manual procedure 01.02.NB Undertray - Front - Renew).
9. Lower vehicle.
10. Install throttle body duct.
11. Connect breather pipe quickf its (x2) to air cleaner duct.
12. Fill tank with approximately amount of displaced oil and replace cap.
13. Use handbook procedure to check oil level.
14. Top up coolant.
Thermostat - Renew
Removal
1. Drain Coolant (refer to Workshop Manual procedure 03.03.AD Coolant - Drain and Refill).
2. Release breather valve (bolt x1) and tie aside.
3. Unclip engine harness for access (x4).
4. Remove one end of engine breather hoses for access (x3).
Repair Operation Time (ROT)
A030243
Repair Operation Time (ROT)
A030244