steering ASTON MARTIN V8 VANTAGE 2010 Owner's Manual

Engine Assembly (03.00)
Engine (03.00)
Issue 5, January 2010 Workshop Manual 3-0-7
25. Disconnect heater re turn hose (quickfit).
26. Disconnect expansion tank to engine (bleed) hose and body clips (x2).
Booster Hose Removal
27. Disconnect vacuum hose from booster.
P.A.S. Removal
28. Remove oil from reservoir (syringe).
29. Disconnect H.P. pipe from pump.
30. Remove PAS reservoir from bracket (bolt x1).
31. Remove hoses (x2) from PAS re servoir (refer to Figure 6).
32. Remove suction hose to body P-clip (bolt x1).
33. Remove pipes from steering rack (bolt x1).
Oil Tank Removal
34. Drain oil tank.
35. Disconnect breather hose from tank (quickfit) (refer to Figure 7). 36. Disconnect oil pipes from tank
(x3) (refer to Figure 8).
37. Remove oil tank (bolts x4) (refer to Figure 9).
38. Disconnect oil pipe from oil thermostat.
A/C Removal
39. Recover refrigerant (refer to Workshop Manual procedure 12.03.FA Refriger ant Gas - Recover/Recharge
- Renew).
40. Disconnect compressor clutch multiplug (access).
Figure 6
WA R N I N G
DO NOT GET USED ENGINE OIL ON YOUR SKIN. USED ENGINE OIL CAN BE HARMFUL.
Figure 7
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Figure 8
Figure 9
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Engine Assembly (03.00)
Engine (03.00)3-0-8 Workshop Manual Issue 5, January 2010
41. Remove bolt (x1) HP pipe to bracket (refer to Figure 10).
42. Remove pipes from compressor (bolts x2) and move aside (refer to Figure 11).
43. Remove bolts (x2) LP pipe to body P-clips and move
aside (refer to Figure 12). Steering Removal
44. Disconnect steering column link to steering rack and tie
aside (refer to Figure 13).
Electrical Removal
45. Disconnect RH indicator repeater light unit multiplug.
46. Remove fir tree clips (x4) for harness of repeater and screen wash system.
47. Remove fir tree clips ECM harness (x2).
48. Remove attachment bolts (x3) from cover plate (ECM and plate will drop down).
49. Disconnect ECM multiplugs (x3).
50. Remove ECM (refer to Figure 14).
Figure 10
Figure 11
Figure 12
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Figure 13
Figure 14
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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
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Figure 24
Figure 25
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Engine Assembly (03.00)
Engine (03.00)
Issue 5, January 2010 Workshop Manual 3-0-13
31. Recharge refrigerant (refer to Workshop Manual procedure 12.03.FA Refrigerant Gas - Recover/Recharge
- Renew).
Steering Install
32. Connect steering column link to steering rack (bolt x1) (refer to Figure 31).
Figure 31
Electrical Install
33. Feed harness into inner wing area (refer to Figure 32).
Figure 32
34. Install fusebox to bracket.
35. Install earth lead to fusebox.
36. Install battery lead to fusebox (1x nut and rubber cover). 37. Install multiplugs to fuse box (refer to Figure 33).
Figure 33
38. Install fusebox bracket fixings (refer to Figure 34).
Figure 34
39. Install ECM and connect mu
ltiplugs to ECM (through
cover plate) (refer to Figure 35).
Figure 35
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Lubrication System (03.02)
Engine (03.00)
Issue 5, Janauary 2010 Workshop Manual 3-2-11
3. Remove pipes from oil tank (refer to Figure 1).
Figure 1
4. Raise vehicle on ramp.
5. Remove undertray (refer to Workshop Manual procedure. 01.02.NB Undertray - Front - Renew).
6. Remove pipe from oil thermostat (position container to catch oil) (refer to Figure 2).
Figure 2
Installation
1. Install pipe to oil thermostat (torque) ensure correct alignment in oil tank bracket.
2. Install undertray (refer to Workshop Manual procedure 01.02.NB Undertray - Front - Renew).
3. Lower vehicle on ramp.
4. Install oil pipe to tank.
5. Install throttle body duct.
6. Connect breather pipe quickf its (x2) to air cleaner duct.
7. Fill tank with approximately amount of displaced oil and replace cap.
8. Use handbook procedure to check oil level.
Oil Pump Inlet Tube Assembly - Renew
Removal
1. Remove the PAS pump (refer to Workshop Manual procedure 03.05.AA Pump - Power Steering - Renew).
2. Remove pipe from oil contro ller (position container to
catch oil).
3. Remove bolt, pipes to bracket (refer to Figure 1).
Figure 1
4. Remove LH exhaust manifo ld (refer to Workshop
Manual procedure 09.00.CD Gasket - Exhaust Manifold
- LH - Renew).
5 . R e m o v e h a r n e s s t o p i p e c l i p ( r e f e r t o F i g u r e 2 ) .
Figure 2
6. Remove bolts that attach the oil pipes to block.
7. Release both pipes from bl ock and remove inlet pipe.
Installation
1. Renew O-ring on remaining oil pipe.
2. Install inlet pipe and position both pipes into block.
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Repair Operation Time (ROT)
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Lubrication System (03.02)
Engine (03.00)3-2-12 Workshop Manual Issue 5, Janauary 2010
3. Install bolts that attach th e oil pipes to block (torque).
4. Install LH exhaust manifold (refer to Workshop Manual
procedure 09.00.CD Gasket - Exhaust Manifold - LH -
Renew).
5. Install bolt, pipes to bracket.
6. Install harness clip to pipe.
7. Install pipe to oil controller (torque).
8. Install P.A.S pump (refer to Workshop Manual procedure 03.05.AA Pump - Power Steering - Renew).
9. Fill tank with approximately amount of displaced oil and replace cap.
10. Use handbook procedure to check oil level.
Oil Pump Inlet Tube Assembly - Renew
Removal
1. Remove the PAS pump (refer to Workshop Manual procedure 03.05.AA Pump - Power Steering - Renew).
2. Remove pipe from oil controller (position container to catch oil).
3. Remove bolt, pipes to bracket (refer to Figure 1).
Figure 1
4. Remove LH exhaust manifold (refer to Workshop Manual procedure 09.00.CD Gasket - Exhaust Manifold
- LH - Renew). 5 . R e m o v e h a r n e s s t o p i p e c l i p ( r e f e r t o F i g u r e 2 ) .
Figure 2
6. Remove bolts that attach the oil pipes to block.
7. Release both pipes from bl
ock and remove inlet pipe.
Installation
1. Renew O-ring on remaining oil pipe.
2. Install inlet pipe and position both pipes into block.
3. Install bolts that attach the oil pipes to block (torque).
4. Install LH exhaust manifold (refer to Workshop Manual
procedure 09.00.CD Gasket - Exhaust Manifold - LH -
Renew).
5. Install bolt, pipes to bracket.
6. Install harness clip to pipe.
7. Install pipe to oil controller (torque).
8. Install P.A.S pump (refer to Workshop Manual procedure 03.05.AA Pump - Power Steering - Renew).
9. Fill tank with approximatel y amount of displaced oil and
replace cap.
10. Use handbook procedure to check oil level.
Oil Pump Outlet Tube Assembly - Renew
Removal
1. Remove PAS pump (refer to Workshop Manual procedure 03.05.AA Pump - Power Steering - Renew).
Repair Operation Time (ROT)
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Repair Operation Time (ROT)
ItemCode
Oil Pump Outlet Tube Assembly -
Renew 03.02.CF
WAR NI NG
DO NOT GET USED ENGINE OIL ON YOUR SKIN. USED ENGINE OIL CAN BE HARMFUL.
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Lubrication System (03.02)
Engine (03.00)
Issue 5, Janauary 2010 Workshop Manual 3-2-13
2. Remove pipe from oil tank (position container to catch oil) (refer to Figure 1).
Figure 1
3. Remove bolt, pipes to bracket (refer to Figure 2).
Figure 2
4. Remove LH exhaust manifold (refer to Workshop Manual procedure 09.00.CD Gasket - Exhaust Manifold
- LH - Renew).
5. Remove harness to pipe clip (refer to Figure 3).
Figure 3
6. Remove bolts that attach the oil pipes to block.
7. Release both pipes from block and remove outlet pipe.
Installation
1. Renew O-ring on remaining oil pipe.
2. Install outlet pipe and position both pipes into block.
3. Install bolts that attach the oil pipes to block (torque).
4. Install bolt, pipes to bracket.
5. Install harness clip to pipe.
6. Install pipe to oil tank (torque).
7. Install LH exhaust manifold (refer to Workshop Manual
procedure 09.00.CD Gasket - Exhaust Manifold - LH -
Renew).
8. Install P.A.S pump (refer to Workshop Manual procedure 03.05.AA Pump - Power Steering - Renew).
9. Fill tank with approximately amount of displaced oil and replace cap.
10. Use handbook procedure to check oil level.
Oil Thermostat Cooler Pipe Assembly -
Renew
Removal
1. Raise vehicle on ramp.
2. Remove undertray (refer to Workshop Manual procedure 01.02.NB Undertray - Front - Renew).
3. Remove LH air filter box (refer to Workshop Manual
procedure 03.12.AB Air Filter Box LH Renew).
4. Remove pipe from oil thermo stat (position container to
catch oil) (refer to Figure 1).
Figure 1
5. Unclip pipe (x4) from inner wing.
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Repair Operation Time (ROT)
A030240

Cooling System (03.03)
Engine (03.00)
Issue 5, Janauary 2010 Workshop Manual 3-3-7
5. Raise expansion tank sufficient to disconnect multiplug, release clip, disconnect hose.
6. Remove expansion tank.
Install
1. Position expansion tank, connect multiplug , install hose and secure with clip.
2. Install nut and bolt, tighten to correct torque.
3. Install hoses (x3) on expansion tank, secure with clips (x3).
4. Install LH cross brace, inst all bolts (x4) (torque with
vehicle on level ground).
5. Refill expansion tank to correct level with correct
coolant fluid mixture.
6. Clean up any spilled coolant fluid.
Coolant Recovery Tank Assembly -
Remove and Install
Remove
1. Raise the vehicle and make it safe.
2. On Roadster vehicles, re move the centre undertray.
3. Remove the left side front wheel.
4. Remove the five or six M6 Torx-head screws that attach the rear of the wheelarch liner.
5. Remove the self-tapping screw that attaches the rear of the wheelarch liner into the wheelarch.
6. Turn the steering fully to the left.
7. Move the rear of the wheela rch liner away to get access
to the recovery tank. 8. Release the clip that attaches each of the two hoses (2)
to the recovery tank and release the hoses (refer to
Figure 1).
Figure 1
9. Remove the two M6 screws (3) that attach the recovery tank to the body and remove the recovery tank.
Install
1. Put the recovery tank in position on the body.
2. Install and tighten the two M6 attachment screws (3).
3. Connect the two hoses (2) to the recovery tank.
4. Put the clip back in position on each hose.
5. Put the wheelarch liner back into position.
6. Turn the steering to the centre position.
7. Install the self-tapping screw that attaches the rear of the wheelarch liner into the wheelarch.
8. Install the five or six M6 Torx-head screws that attach the rear of the wheelarch liner.
9. Install the front left roadwheel.
10. On Roadster vehicles, install the centre undertray.
11. Lower the vehicle.
12. Do a check of the coolant level and fill if necessary.
Repair Operation Time (ROT)

Engine Management System (03.14)
Engine (03.00)
Issue 5, Janauary 2010 Workshop Manual 3-14-3
Removal
1. Raise vehicle on ramp.
2. Remove rear exhaust silencer (refer to Workshop Manual procedure 09.00.KA Silencer and Bypass Valve
Assembly - Remove for Access and Refit).
3. Disconnect multiplugs (x2), HEGO sensors.
4. Secure sufficient lengths of string to HEGO sensor multiplugs for assembly purposes.
5. Loosen LH and RH clamp nuts, catalysts to centre pipes.
6. With assistance, manoeuvre exhaust centre pipe assembly rearwards to release from catalysts.
7. Remove nuts (x3), catalyst to exhaust manifold.
8. Release and support weight of LH catalyst from exhaust manifold.
9. Manoeuvre HEGO sensor leads and remove cable tie. Release HEGO sensor leads from behind heat shield.
Remove string from HEGO multiplugs.
10. Remove catalyst assembly.
11. Remove and discard gasket.
12. Remove HEGO sensors from catalyst.
Installation
1. Clean catalyst, mating joint faces and HEGO sensors.
2. Install and tighten HEGO sensor to catalyst.
3. Apply proprietary exhaust se alant around clamp joints.
4. Install new gasket to exhaust manifold.
5. Position catalyst, secure string (x2) to HEGO multiplugs, feed sensor leads behind heat shield. Install catalyst to
exhaust manifold.
6. Instal land tighten nuts (x3), catalyst to exhaust manifold.
7. Align centre pipe assembly to catalyst, tighten clamp
nuts to.
8. Remove string (x2), conne ct multiplugs (x2), HEGO
sensors.
9. Install rear exhaust silencer (refer to Workshop Manual procedure 09.00.KA Silencer and Bypass Valve
Assembly - Remove for Access and Refit).
10. Lower vehicle on ramp.
Left Side Powertrain Control Module
(PCM) (Coupe Only) - Remove and
Install
Remove
1. Disconnect the ba ttery ground cable.
2. Remove the wheel and tyre. (refer to Workshop Manual procedure 04.04.EC - Wheel and Tyre)
3. Remove the six rear screws that attach the wheel-arch liner to the body.
4. Remove the rear screw that attaches the wheel-arch liner to the body.
5. Turn the steering fully to the right.
6. Move the wheel arch liner to get access to the Powertrain Control Module (PCM).
7. Disconnect the electrical connector from the direction
indicator.
8. Release the four fi r-tree clips that attach the wiring
harness for the direction indi cator and the screen wash
system.
9. Release the two fir tree clips that attach the wiring harness for the PCM.
10. Remove the three bolts that attach the PCM bottom bracket and PCM to the PCM top bracket.
11. Disconnect the three electrical connectors from the PCM.
12. Remove the PCM.
Install
1. Put the PCM in position.
2. Connect the three electrical connectors to the PCM.
3. Align the PCM to the top bracket.
4. Align the bottom bracket to the PCM.
5. Install and tighten the three bolts that attach the PCM bottom bracket and PCM to the PCM top bracket.
6. Install the two fir tree clips that attach the wiring harness for the PCM.
7. Attach the four fir-tree cl ips that attach the wiring
harness for the direction indi cator and the screen wash
system.
8. Connect the electrical connector to the direction indicator.
9. Put the wheel-arch liner into the correct position.
10. Install and tighten the rear screw that attaches the wheel-arch liner to the body.
11. Install and tighten the six rear screws that attach the wheel-arch liner to the body.
12. Move the steering to the centre position.
13. Connect the battery ground cable.
14. Install the wheel and tyre. (04.04.EC - Wheel and Tyre)
15. Connect AMDS.
16. Use AMDS to do a test of the PCM. (00.06.AD - AMDS Operation Check)
WA R N I N G
THE EXHAUST SYSTEM WILL BE VERY HOT AFTER OPERATION. LET THE EXHAUST SYSTEM COOL
BEFORE YOU DO WORK. IF YOU DO NOT, SEVERE
INJURY CAN OCCUR
Repair Operation Time (ROT)

Engine Management System (03.14)
Engine (03.00)3-14-4 Workshop Manual Issue 5, Janauary 2010
Left Side Powertrain Control Module
(PCM) (Roadster Only) - Remove and
Install
Remove
1. Disconnect the battery ground cable.
2. Lift the vehicle on a four-post lift.
3. Remove the centre undertray. (refer to Workshop Manual procedure 01.02.MB - Centre Undertray)
4. Lower the vehicle.
5. Lift the vehicle on a two-post lift.
6. Remove the wheel and tyre. (refer to Workshop Manual procedure 04.04.EC - Wheel and Tyre)
7. Remove the six rear screws that attach the wheel-arch liner to the body.
8. Remove the rear screw that attaches the wheel-arch liner to the body.
9. Turn the steering fully to the right.
10. Move the wheel-arch liner to get access to the Powertrain Control Module (PCM).
11. Disconnect the electrical connector from the direction indicator.
12. Release the four fir tree cl ips that attach the wiring
harness for the direction indicator and the screen wash
system.
13. Release the two fir tree clips that attach the wiring harness for the PCM.
14. Remove the three screws that attach the PCM bottom bracket and PCM to the PCM top bracket.
15. Disconnect the three elec trical connectors from the
PCM.
16. Remove the PCM.
Install
1. Put the PCM in position.
2. Connect the three electrical connectors to the PCM.
3. Align the PCM with the top bracket.
4. Align the bottom bracket with the PCM.
5. Install and tighten the three screws that attach the PCM bottom bracket and PCM to the PCM top bracket.
6. Install the two fir tree clips that attach the wiring harness for the PCM.
7. Attach the four fir tree clips that attach the wiring harness for the indicator and the screen wash system.
8. Connect the electrical connector to the indicator.
9. Put the wheel-arch liner into the correct position.
10. Install and tighten the rear screw that attaches the wheel-arch liner to the body. 11. Install and tighten the six rear screws that attach the
wheel-arch liner to the body.
12. Install the centre undertray. (refer to Workshop Manual procedure 01.02.MB - Centre Undertray)
13. Install the wheel and tyre. (refer to Workshop Manual procedure 04.04.EC - Wheel and Tyre)
14. Move the steering to the centre position.
15. Connect the battery ground cable.
Repair Operation Time (ROT)