2010 ASTON MARTIN V8 VANTAGE fuse

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).

Anti-lock Braking System (ABS) (06.09)
Brake system (06.00)
Issue 4, November 2008 Workshop Manual 6-9-3
Engine Intervention
In the event of wheel-slip the ABS / DSC module calculates
the torque, which should be applied by the engine to reduce
the wheel-slip (this torque does not exceed driver demand).
Engine torque reduction is then requested from the PCM via
the CAN bus. The PCM, in response to these signals, reduces
engine torque by controlling the ignition and fuelling. A
traction control gearshift pattern is automatically selected
within the automatic transmission software whenever
traction control is active.
Brake Intervention
This function operates by increasing the pressure in the
brake caliper of the slipping wheel, by closing the separation
valve and the inlet valve of the non-slipping wheel and
running the modulator pump. This takes fluid from the fluid
reservoir via the non-actuated master cylinder and
pressurizes the brake caliper. The pressure is modulated at
the caliper via the inlet and outlet valves to achieve the
desired wheel-slip target to maximize traction.
ABS / DSC Circuit
Specifications
SR,05UR,05YR,0.5NR,0.5
WR,05NR,05
YG,05WG,05
YU,05WU,05
W,05N,05
W,0.5U,0.5R,0.5
P,0.5Y,0.5
B,0.5WG,0.5GB,0.5
B,0.5BG,0.5
GW,0.5
P,0.5
U,0.5
U,3.0
BK,1.0BK,1.0
P,0.35P,0.35P,0.35 U,3.0
WG,05YG,05
WU,05
SR,05UR,05YR,0.5NR,0.5
WG,05YG,05
WU,05
WG,05YG,05
WU,05YU,05YU,05YU,05Module-ABS
OBD2-Body (B)
Earth-Module ABSEarth-Module ABS
C1184-18C2410-6
Sensor-Brake Pressure
Sensor-Brake Pedal Travel
Sensor-Rear ABS-LH
C0746-7C0746-6
C0746-5
Switch-Brake Boost
Sensor-Yawrate / Acceleration
C2411-6C2411-5C2411-4
C2411-3
C0144-7C0144-3
C0144-2
Sensor-Front ABS-LH
Sensor-Front ABS-RH
C2410-10C2410-9
C2410-8
Sensor-Rear ABS-RH
C0746-4C0144-1C2410-7
C0877-7
K-LINESPL50-KL/FA
C0362-1C0434-1
C2444-2
SIGC2444-1
GND
C2444-3
SENSP
C2446-2
GNDC2446-1
SENSPT
C2446-3
SIG
C0501-47
GNDC0501-16
GND
C0501-2K-LINE
C0501-24
GND
C0501-31
PWM
C0501-30
NC
C0501-25
CAN HS-
C0501-28
SIGC0501-27
NO
C0501-29
CAN HS+C0501-6
CLUST_SP
C0501-17
PWR
C0501-5
GND
C0501-32BATT FEED
C0501-7
SENSPT
C0501-3 SIG
C0501-20 SIGC0501-19
GND
C0501-18 SENSP
C0501-4IGN FEED
C0501-46
F/L/GNDC0501-45
F/L/SIG
C0501-42
R/R/GNDC0501-43
R/R/SIG
C0501-36
R/L/SIG
C0501-34
F/R/SIGC0501-33
F/R/GND
C0501-1
BATT FEEDC0501-37
R/L/GND
C2448-5
C2448-3
C2448-2C2448-1
C2448-4
C1656-3 CLUS_SPC1656-2
CAN HS+C1656-1 CAN HS-
C1656-5
GND
C0516-2-C0516-1+
C0517-2
-C0517-1+
C0502-1
+
C0503-2 -C0503-1+
C0502-2 -
Sensor
Steering Angle
Sheet 61
F4
30.0 AmpsRelay 1
Underbonnet Fusebox
DIODE 1
F28
10.0 Amps
F20
30.0 Amps
F19
30.0 Amps
Earth
Steering Angle
Sensor
C0576-1
C0577-4C2608-1 VBATT
C0573-2
C0571-3
C0573-3
C0578-8SPL5-VIGN/FOR
C1672-5
VPWRC1672-8
GND
011-6-003
Oils/Greases
Brake FluidCastrol Response Super Dot 4
Torque Figures
DescriptionNm.lb. / ft.
Modulator to Bracket 5 4
Modulator / Bracket to body 9 7
Brake hose unions 17 1413
10.5
17 Nm. 17 Nm.
17 Nm.
14 Nm.
14 Nm. 14 Nm.

Silencer Assembly (09.01)
Exhaust (09.00)
Issue 5, January 2010 Workshop Manual 9-1-5
9. Release the two wiring harn esses for the HEGO sensor
from the clip on the heat shield.
10. Release the HEGO sensor from the catalytic converter.
11. Install an applicable length of string to the wiring harness and the electrical connector for the HEGO sensor.
12. Use the string to put the wiring harness for the HEGO
sensor behind the heat shield.
13. Release the string from the electrical connector for the HEGO sensor.
14. Remove the HEGO sensor.
15. Clean the component mating faces.
Install
1. Put the HEGO sensor into position.
2. Attach an applicable length of string to the wiring harness for the HEGO sensor.
3. Use the string to put the wiring harness for the HEGO
sensor behind the heat shield.
4. Remove and discard the string.
5. Install the HEGO sensor into the catalytic converter.
6. Tighten the HEGO sensor.
7. Put the heat shield into position.
8. Install and tighten the two bolts that attach the heat shield to the torque tube.
9. Install the two wiring harnesses for the HEGO sensor into the clip on the heat shield.
10. Put the bracket into position.
11. Install and tighten the two bolts that attach the bracket to the engine.
12. Connect the two electrical connnectors to the HEGO
sensor.
13. Install the two electrical connnectors for the HEGO sensor into the bracket.
Silencer and Bypass Valve Assembly-
Remove for Access/Refit-Coupe Only
Removal
1. Raise vehicle on ramp.
2. Remove rear undertray (refer to Workshop Manual procedure 01.02.PB Undertray - Rear - Renew). 3. Remove Allen bolts (x4), bumper diffuser to mounting
brackets. Remove diffuser, collect securing brackets.
4. Disconnect both by-p ass valve vacuum lines.
5. Remove bolts (x4), rear exhaust pipes to silencer. Collect springs from bolts.
6. Remove bolts (x4), securing LH and RH silencer rear hanger brackets to body.
7. Remove bolts (x4), silencer front mountings to subframe.
8. Position suitable lifter to support weight of silencer. With assistance, remove silencer.
9. Remove both rear rubber mountings and hanger brackets from silencer.
Installation
1. Clean muffler and mating faces on rear pipes.
2. Position silencer on lifter. Install silencer, position rear
hangers, install and torque tighten bolts (x4).
3. Position front mountings to subframe, install and torque
tighten bolts (x4).
4. Align silencer to rear pipes, install springs (x4), install and torque tighten bolts (x4).
5. Check silencer to rear pipes for correct alignment and clearances.
6. Connect lines to both by-pass vacuum valves.
7. Position mounting brackets, install rear bumper diffuser. Install and tighten Allen bolts.
8. Install rear undertray (refer to Workshop Manual procedure 01.02.PB Undertray - Rear - Renew).
9. Lower vehicle on ramp.
Silencer and Bypass Valve Assembly-
Remove for Access/Refit-Roadster Only
Removal
1. Raise vehicle on ramp.
CAUTION
Turn the electrical harness for the HEGO sensor when
you remove the sensor in the step that follows. If you do not, the harness can be damaged.
CAUTION
Turn the electrical harness for the HEGO sensor when
you remove the sensor in the step that follows. If you do not, the harness can be damaged.
Repair Operation Time (ROT)
WA R N I N G
THE EXHAUST SYSTEM WILL BE VERY HOT AFTER
OPERATION. LET THE EXHAUST COOL BEFORE YOU DO WORK. IF YOU DO NO T, PESONAL INJURY CAN
OCCUR.
WA R N I N G
GET THE AID OF ONE MORE PERSON WHEN YOU
REMOVE THE REAR EXHAUST SILENCER.
THE SILENCER IS HEAVY .
WA R N I N G
GET THE AID OF ONE MORE PERSON WHEN YOU INSTALL THE REAR EXHAUST SILENCER.
THE SILENCER IS HEAVY .
Ensure correct alignment of exhaust pipes and silencer before tightening of fixing clamps.
Repair Operation Time (ROT)

Silencer Assembly (09.01)
Exhaust (09.00)9-1-6 Workshop Manual Issue 5, January 2010
2. Clean silencer and mating faces on rear pipes.
3. Remove Rear RH wheel arch liner (refer to Workshop Manual procedure 01.02.HB Wheel Arch Liner - Rear -
RH - Renew).
4. Remove rear undertray (refer to Workshop Manual procedure 01.02.PB Undertray - Rear - Renew).
5. Apply a proprietary exhaust sealant around all clamp joints
6. Remove Allen bolts (x2), loosen Allen bolts (x2), bumper diffuser to mounting brackets and remove diffuser.
7. Position silencer on lifter.
8. Install silencer, position rear hangers to body, install and torque tighten bolts (x4).
9. Remove Rear LH wheel arch liner.
10. Disconnect both by-pass valve vacuum lines.
11. Remove Allen bolts (x2), loosen Allen bolts (x2), bumper diffuser to mounting brackets and Remove diffuser.
12. Position front mountings to subframe, install and torque tighten bolts (x4).
13. Loosen clamp nuts (x2), remove stub pipes (x2).
14. Disconnect both by-pass valve vacuum lines.
15. Align silencer to rear pipes, install springs onto bolts (x4), install and torque tighten bolts (x4).
16. Remove bolts (x4), rear exha ust pipes to silencer. Collect
springs from bolts.
17. Loosen clamp nuts (x2), remove stub pipes (x2).
18. Install stub pipes (x2), centralise stub pipes to exhaust trim finisher. Torque ti ghten clamp nuts (x2).
19. Remove bolts (x4), securing LH and RH silencer rear
hanger brackets to body.
20. Remove bolts (x4), rear exhaust pipes to silencer and collect springs from bolts.
21. Check silencer to rear pipes for correct alignment and clearances.
22. Remove bolts (x4), silencer front mountings to subframe.
23. Remove bolts (x4), securing LH and RH silencer rear
hanger brackets to body.
24. Connect lines to both by-pass vacuum valves.
25. Position suitable lifter to support weight of silencer.
With assistance, remove silencer.
26. Remove bolts (x4), silencer front mountings to subframe.
27. Install rear bumper diffuser and install and tighten Allen
bolts (x4).
28. Install Rear RH wheel arch liner (refer to Workshop Manual procedure 01.02.HB Wheel Arch Liner - Rear -
RH - Renew).
Installation
1. Position suitable lifter to su pport weight of silencer. With
assistance, remove silencer.
2. Clean silencer and mating faces on rear pipes.
3. Install Rear LH wheel arch liner.
4. Apply a proprietary exhaust sealant around all clamp joints 5. Lower vehicle on ramp.
6. Position silencer on lifter. Install silencer, position rear
hangers to body, install and torque tighten bolts (x4).
7. Position front mountings to subframe, install and torque tighten bolts (x4).
8. Align silencer to rear pipes, install springs onto bolts (x4), install and torque tighten bolts (x4).
9. Install stub pipes (x2), centralise stub pipes to exhaust trim finisher and torque tighten clamp nuts (x2).
10. Check silencer to rear pipes for correct alignment and clearances.
11. Connect lines to both by-pass vacuum valves.
12. Install rear bumper diffuser and install and tighten Allen bolts (x4).
13. Install rear undertray (r efer to Workshop Manual
procedure 01.02.PB Undertray - Rear - Renew).
14. Lower vehicle on ramp.
Silencer and Bypass Valve Assembly-
Renew
Removal
1. Raise vehicle on ramp.
2. Coupe Only - Remove rear undertray (refer to
Workshop Manual procedure 01.02.PB Undertray -
Rear - Renew).
3. Roadster Only - Remove RH rear wheel arch liner (refer
to Workshop Manual procedure 01.02.HB Wheel Arch
Liner - Rear - RH - Renew).
4. Roadster Only - Remove LH rear wheel arch liner.
5. Remove Allen bolts (x2, loosen Allen bolts (x2), securing bumper diffuser to mounting brackets. Remove diffuser.
6. Disconnect both by-pass valve vacuum lines.
7. Loosen clamp nuts (x2), remove stub pipes (x2).
8. Remove bolts (x4), rear exha ust pipes to silencer. Collect
springs from bolts.
9. Remove bolts (x4), securing LH and RH silencer rear
hanger brackets to body.
10. Remove bolts (x4), muffler front mountings to subframe. Remove mountings from silencer.
Repair Operation Time (ROT)
ItemCode
Silencer and Bypass Valve Assembly-
Renew 09.00.KB
WAR NI NG
THE EXHAUST SYSTEM WILL BE VERY HOT AFTER
OPERATION. LET THE EXHA UST COOL BEFORE YOU
DO WORK. IF YOU DO NO T, PESONAL INJURY CAN
OCCUR.
WAR NI NG
GET THE AID OF ONE MORE PERSON WHEN YOU
REMOVE THE REAR EXHAUST SILENCER.
THE SILENCER IS HEAVY .

Silencer Assembly (09.01)
Exhaust (09.00)
Issue 5, January 2010 Workshop Manual 9-1-7
11. Position suitable lifter to support weight of silencer.
With assistance, remove silencer.
12. Remove both rear rubber mountings and hanger brackets from silencer.
Installation
1. Clean silencer and mating faces on rear pipes and stub pipes.
2. Install both rear rubber mountings and hanger brackets to silencer.
3. Position silencer on lifter . Install silencer, position
hangers, install and tighten bolts (x4).
4. Install front mountings to silencer, install and tighten bolts (x4).
5. Align silencer to rear pipes. Install springs (x4), and torque tighten bolts (x4).
6. Install and align stub pipes (x2) to silencer and trims in bumper. Align and tighten clamp bolts.
7. Check silencer to rear pipes for correct alignment and clearances.
8. Install stub pipes (x2), insta ll clamps (x2), centralise stub
pipes to exhaust trim finisher, torque tighten clamp nuts
(x2).
9. Check silencer to rear pipes for correct alignment and clearances.
10. Connect lines to both by-pass vacuum valves.
11. Install rear bumper diffuse r. Install and tighten Allen
bolts (x4).
12. Roadster Only - Install RH rear wheel arch liner (refer to
Workshop Manual procedure 01.02.HB Wheel Arch
Liner - Rear - RH - Renew).
13. Roadster Only - Install LH rear wheel arch liner.
14. Coupe Only - Install rear undertray (refer to Workshop
Manual procedure 01.02.PB Undertray - Rear - Renew).
15. Lower vehicle on ramp.
Exhaust Rear Silencer Mounting Rubber-
Renew
Removal
1. Raise vehicle on ramp. 2. Remove Allen bolts (x4), bumper diffuser to mounting
brackets. Remove diffuser, collect mounting brackets.
3. Remove bolts (x2), securing silencer rear hanger brackets to body.
4. Release/remove rubber mounting and hanger bracket from silencer bracket.
5. Remove rubber mounting from hanger bracket.
Installation
1. To aid assembly, apply liquid soap to rubber mounting .
2. Install rubber mounting on hanger bracket.
3. Install rubber mounting on muffler bracket.
4. Align hanger bracket to body, install and torque tighten bolts (x2).
5. Position mounting brackets, install bumper diffuser, install and torque tighten Allen bolts (x4).
6. Lower vehicle on ramp.
Exhaust System-Renew
1. Disconnect vehicle battery.
2. Raise vehicle on ramp.
3. Remove RH exhaust manifold.
4. Remove RH front wheel arch liner (refer to Workshop Manual procedure 01.02.GB Wheel Arch Liner - Front -
RH - Renew).
5. Remove LH front wheel arch liner (refer to Workshop
Manual procedure 01.02.FB Wheel Arch Liner - Front -
LH - Renew).
6. Remove heatshield deflector, front floor (refer to Workshop Manual procedure 09.04.AA Heatshield -
Front Floor - Renew).
7. Loosen EGR pipe in valve.
8. Remove (nuts x2) EGR pipe from manifold, discard
gasket and tie aside.
WA R N I N G
GET THE AID OF ONE MORE PERSON WHEN YOU INSTALL THE REAR EXHAUST SILENCER.
THE SILENCER IS HEAVY .
Ensure correct alignment of exhaust pipes and silencer before tightening of fixing clamps.
Repair Operation Time (ROT)
WA R N I N G
THE EXHAUST SYSTEM WILL BE VERY HOT AFTER
OPERATION. LET THE EXHAUST COOL BEFORE YOU DO WORK. IF YOU DO NO T, PESONAL INJURY CAN
OCCUR.
Repair Operation Time (ROT)

Silencer Assembly (09.01)
Exhaust (09.00)9-1-8 Workshop Manual Issue 5, January 2010
9. Remove nut (x8) securing RH exhaust manifold to cylinder head (refer to Fig. 1).
10. Remove nut (x2) on RH engine mounting.
11. Raise engine by approximately 25mm.
12. Remove RH exhaust manifold from vehicle and discard
gasket.
13. Remove heatshield from manifold (bolts x4)
14. Remove nuts (x8) securing LH exhaust manifold to
cylinder head.
15. Remove exhaust manifold, remove and discard gasket.
Installation
1. Clean LH exhaust manifold and mating face on cylinder head. Install new manifold gasket.
2. Install LH exhaust manifold to cylinder head.
3. Install and torque tighten nuts (x8) securing exhaust manifold to cylinder head.
4. Clean exhaust manifold and mating face on engine. Install new gasket to engine.
5. Install heatshield to manifold (bolts x4)
6. Install RH exhaust mani fold to cylinder head.
7. Install nut (x8) securing manifold to cylinder head
(torque).
8. Lower engine.
9. Install nuts (x2) on engine mounts (torque).
10. Install (nuts x2) EGR pipe from manifold, clean mating face and fit new gasket (torque).
11. Install heatshield deflector, front floor (refer to Workshop Manual procedure 09.04.AA Heatshield -
Front Floor - Renew).
12. Tighten EGR pipe in valve (torque).
13. Install RH front wheel arch liner (refer to Workshop Manual procedure 01.02.GB Wheel Arch Liner - Front -
RH - Renew
14. Install LH wheel arch liner (refer to Workshop Manual procedure 01.02.FB Wheel Arch Liner - Front - LH -
Renew).
15. Lower vehicle on ramp. 16. Connect vehicle battery.
Exhaust System (Excluding Manifold/
Downpipes)-Renew
Removal
1. Raise vehicle on ramp.
2. Remove undertrays - vehicle set (refer to Workshop
Manual procedure 01.02.PD Undertrays - Vehicle Set -
Renew).
3. Remove Allen bolts(x4), bumper diffuser to mounting brackets. Remove diffuser
4. Disconnect both by-pass valve vacuum lines.
5. Remove bolts (x4), securing LH and RH silencer rear
hanger brackets to body. Remove hanger brackets.
6. Remove bolts (x4), rear exha ust pipes to silencer. Collect
springs from bolts
7. Remove bolts (x4), silencer front mountings to subframe. Remove mountings from silencer.
8. Position suitable lifter to support weight of silencer. with assistance, remove silencer.
9. Mark rear stub pipes to si lencer for assembly purposes.
10. Loosen clamps (x2), rear stub pipes to silencer. Remove stub pipes and clamps.
11. Remove bolts (x4), remove rear subframe cross brace.
12. Loosen clamps (x2), release RH and LH rear pipes from centre pipe.
13. Remove rear pipes through subframe.
14. Loosen clamps (x2), centre pipe to LH and RH catalysts.
15. Coupe Only - Release centre pipe from mountings, LH
and RH catalysts, remove centre pipe.
16. Roadster Only - Remove centre exhaust mounting bolts
(x4).
17. Release LH and RH catal ysts, remove centre pipe.
18. Disconnect multiplugs (x4), from each catalyst.
19. Coupe Only - Secure sufficient lengths of string to
HEGO sensor multiplugs for assembly purposes.
Figure 1
A090069
Repair Operation Time (ROT)
ItemCode
Exhaust System (Excluding Manifold/
Downpipes)-Renew 09.00.NB
WAR NI NG
TO AVOID PERSONAL INJURY, I.E. SEVERE BURNS TO
THE SKIN, ALLOW EXHAUS T SYSTEM TO COOL
DOWN BEFORE REMOVING EXHAUST SYSTEM COMPONENTS.
WAR NI NG
GET THE AID OF ONE MORE PERSON WHEN YOU
REMOVE THE REAR EXHAUST SILENCER.
THE SILENCER IS HEAVY .
Attach lengths of string to th e HEGO sensor multiplugs. This
enables routing the HEGO sensor harness behind the exhaust heat shield on assembly.

Silencer Assembly (09.01)
Exhaust (09.00)
Issue 5, January 2010 Workshop Manual 9-1-9
20. Coupe Only - Remove cable ties (x2) from LH and RH
HEGO sensor harnesses.
21. Remove nuts (x6), securing each catalyst to exhaust manifolds.
22. With assistance, remove catalysts (x2), release HEGO sensor harnesses from behind heat shield.
23. Coupe Only - Remove string from multiplugs.
24. Discard gaskets (x2) from exhaust manifolds.
25. Coupe Only - Remove bolts (x11), heatshields to centre,
LH and RH rear pipes. Remove heatshields.
Installation
1. Clean heatshields.
2. Coupe Only - Position heatshields to centre, LH and RH
rear pipes. Install and tighten bolts.
3. Install new flange gaskets to exhaust manifolds.
4. With assistance, install both catalysts, install and torque tighten nuts (x6).
5. Roadster Only - Install bolts (x4) and nuts (x2) to
catalyst heatshield.
6. Coupe Only - Feed HEGO sensor harnesses behind
heat shield, secure harnesses with cable ties.
7. Apply exhaust sealant to cent re pipe, install centre pipe
to catalysts and centre mounting. Do not torque clamp
nuts at this stage.
8. Roadster Only - Install centre exhaust mounting bolts
(x4).
9. Apply exhaust sealant to LH and RH rear pipes.
10. Install LH and RH rear pi pes to centre pipe. Do not
torque clamp nuts at this stage.
11. Install both rear rubber mountings and hanger brackets to silencer.
12. Position silencer on lifter . Install silencer, position
hangers, install and tighten bolts (x4).
13. Install front mountings to silencer, install and tighten bolts (x4).
14. Align silencer to rear pipes, install springs (x4) and bolts (x4). Do not torque bolts at this stage.
15. Install and align stub pipes (x2) to silencer and to trims in
bumper.
16. Align clamps, do not torque tighten.
17. Connect lines to both by-pass vacuum valves.
18. Coupe Only - Remove string from multiplugs.
19. Connect multiplugs to HEGO sensors. 20. Working from front to rear, set all exhaust to body
clearances.
21. Tighten all exhaust fixings to the correct torque.
22. Install subframe cross brace, install and torque tighten bolts (x4).
23. Position mounting brackets, install rear bumper diffuser. Install and tighten Allen bolts.
24. Install undertrays - vehicle set (refer to Workshop Manual procedure 01.02.PD Undertrays - Vehicle Set -
Renew).
25. Lower vehicle on ramp.
Attach lengths of string to th e HEGO sensor multiplugs. This
enables routing the HEGO se nsor harness behind the
exhaust heat shield on assembly.
WA R N I N G
GET THE AID OF ONE MORE PERSON WHEN YOU
INSTALL THE REAR EXHAUST SILENCER.
THE SILENCER IS HEAVY .
Ensure correct alignment of exhaust pipes and silencer before tightening of fixing clamps.