Maintenance; Fuel Rails-Renew - Aston Martin V8 Vantage Workshop Manual

Fuel Charging System (03.04)

Maintenance

Fuel Rails-Renew

Repair Operation Time (ROT)
Item
Fuel Rails-Renew
Removal
1. Depressurise fuel rail (see Workshop Manual procedure
10.01.EK Fuel System - Depressurise).
Removal Not Handed
2. Coolant drain (see Workshop Manual procedure
03.03.AD Coolant - Drain & 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 & nut) (allows
movement).
8. Remove ECM (see Workshop Manual procedure
03.14.BB Engine Control 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 (1x nut &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) & 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 & 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).
3-5-2
29. Release heater hose (x2) and throttle body hose (x2)
from support bracket.
30. Remove booster hose from manifold (V/difficult) and
support clip.
31. Remove harness support bracket (bolt x1, nut x2)
Code
release harness clips (fir tree x3).
03.01.BZ
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).
44. Remove bolts (x2) bracket to manifold (rear) V/difficult.
45. Move manifold (2x people) forward, remove bolt for
purge line p-clip, remove manifold.
46. Remove gaskets and clean mating faces.
Removal - Manifold Parts
47. Remove Injector to rail clips (x8).
48. Remove fuel rail (bolts x4).
Installation
1. Install clips and new o-rings to injectors.
2. Install fuel rail (bolts x4).
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 & 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 quickfits (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).
Workshop Manual October 2005