lock ASTON MARTIN V8 VANTAGE 2010 Workshop Manual

Power Conversion (03.11)
Engine (03.00)3-11-32 Workshop Manual May 2007
23. Remove bolts (x16) securing sump to engine bedplate
(see Figure 13).
Figure 13
24. Release and remove sump.
25. Remove bolts (x8) securing windage tray to engine bedplate, remove windage tray.
26. Mark bearing caps and connecting rods for correct installation (see Figure 14).
Figure 14
27. Rotate crankshaft clockwise to access number 1 cylinder
connecting rod bolts. 28. Remove bolts (x16) securing bearing caps to connecting
rods, remove bearing caps (see Figure 15).
Figure 15
29. Install special tools (303-535) to the connecting rod to prevent damage to crankshaft journal.
30. Carefully push each connecting rod/piston assembly upwards and remove from cylinder bores.
31. Remove special tools from connecting rods.
32. Install bearing caps on connecting rods, install and lightly tighten retaining bolts.
33. Note that piston grade number on crown and thick flange on connecting rod faces to front of engine on RH
bank (A) (see Figure 16).
Figure 16
A030206D
A0311329
Caution
Connecting rod bolts are tor qu
e tightened to yield and
mu st be replaced.
A0311314
A0311332

Power Conversion (03.11)
Engine (03.00)
May 2007 Workshop Manual 3-11-33
34. Note that piston grade number on crown and thick
flange on connecting rod faces to front of engine on LH
bank (B) (see Figure 17).
Figure 17
Installation
1. Clean cylinder bores.
2. Clean connecting rods,
3. Install pistons on connecting rods in their correct orientation, install circlip(s) (see Figure 18)
.
Figure 18
4. Correctly position ring gaps on pistons prior to installation.
5. Remove connecting rod bearing caps.
6. Install bearings in connecting rods and bearing caps.
7. Lubricate cylinder bores, pistons and rings with clean
engine oil.
8. Install special tools (303-535) to the connecting rod to prevent damage to crankshaft journal. 9. Install piston ring clamp to each piston in turn and install
in its respective cylinder bore. Remove piston ring
clamp (see Figure 19).
Figure 19
10. Lubricate crankshaft journals with clean engine oil.
11. Carefully pull each connecting rod into place on each crankshaft journal.
12. Install bearing caps to their relevant connecting rods. Install and torque tighten retaining bolts (x16).
13. Clean windage tray.
14. Install windage tray, install and torque tighten bolts (x8).
15. Clean old sealant from sump flange and engine bedplate.
16. Ensure that sump flange and mating face on engine bedplate are clean and dry.
17. Apply a continuous 3mm diameter bead of RTV sealant to sump flange as recommended.
18. Ensure that there are no gaps in sealant track.
19. Install sump, install and torque tighten bolts (x16) in the correct sequence.
20. Install A/C compressor mounting bracket, install and torque tighten Torx bolts (x4).
21. Lubricate and install new 'O' ring seals to oil pipes.
22. Install oil pipes in sump, install and torque tighten bolts (x2)
23. Install compressor, install and torque tighten bolts (x4).
24. Connect multiplug to A/C compressor.
25. Install LH and RH HEGO se nsor multiplug brackets to
sump. Install and torque tighten bolts (x4).
26. Secure harness clips (x6) in sump.
27. Connect multiplug to crankshaft timing sensor.
28. Connect multiplug to engine electric coolant temperature sensor.
29. Connect multiplug to oil pressure sensor.
Caution
Make sure the piston ring gaps are positioned at
different positions opposite the thrust side of the piston
before installation.
A0311332
A0311333
Caution
Install pistons into cylinder block with the

Power Conversion (03.11)
Engine (03.00)3-11-34 Workshop Manual May 2007
30. Clean oil scavenge pump and mating face on sump.
31. Install oil pump(s) drive sprocket.
32. Install new oil scavenge pump gasket, align on dowels
(x2).
33. Install chain onto oil scavenge pump sprocket.
34. Install oil scavenge pump, align to dowels (x2), Install and torque tighten bolts (x3).
35. Install chain onto oil pump drive sprocket.
36. Clean oil pressure pump and mating face on sump.
37. Install new gasket to sump, align to dowels (x2).
38. Position oil pressure pump, install chain on pump sprocket.
39. Install oil pressure pump, alig n to dowels (x2), Install and
torque tighten bolts (x3).
40. Install chain tensioner, install and torque tighten bolt, remove guide pin.
41. Install crankshaft timing sprocket.
42. Install cylinder head gaskets - engine set (see Workshop Manual procedure 03.01.HW Gasket - Cylinder Head -
Engine Set - Renew With Engine Removed).
Crankshaft Damper Pulley Assembly-
Renew
Removal
1. Remove engine drive belt (see Workshop Manual procedure 03.05.AB Belt - Engine Drive - Renew).
2. Raise vehicle on ramp.
3. Remove bolts (x2), inspection cover to lower crankcase, remove cover.
4. Install tool (303-1185) to restrain flywheel, install and tighten bolts (x2).
5. Install thrust button of tool (303 -1186) in crankshaft,
position tool in pulley, secure with bolts (x2). Tighten
centre bolt, withdraw pu lley from crankshaft.
6. Collect crankshaft pulley, locking ring and special tool thrust button.
7. Remove special tool from pulley. 8. Remove and discard O-ring seal from pulley (see
Figure 1).
Figure 1
Installation
1. Clean crankshaft pulley, locking ring and mating face on
crankshaft.
2. Lubricate and install new O-ring seal in crankshaft pulley.
3. Install crankshaft pulley, locking ring and new pulley bolt.
4. Torque tighten crankshaft pulley bolt. Remove special tool (303-1185) from crankcase.
5. Install inspection cover to lower crankcase, install and tighten bolts (x2).
6. Lower vehicle on ramp.
7. Install engine drive belt (see Workshop Manual procedure 03.05.AB Belt - Engine Drive - Renew).
Crankshaft Front Oil Seal-Renew
Removal
1. Battery isolation switch ‘OFF’.
2. Raise vehicle on ramp.
3. Remove crankshaft pulley (see Workshop Manual procedure 03.11.CP Pulley Assembly - Crankshaft
Damper - Renew).
Repair Operation Time (ROT)
Caution
The bolt thread in the cran kshaft must be cleaned out
before a new crankshaft pulley retaining bolt is installed
Repair Operation Time (ROT)
ItemCode
Crankshaft Front Oi l Seal-Renew 03.11.CQ
A0311321

Power Conversion (03.11)
Engine (03.00)
May 2007 Workshop Manual 3-11-35
4. Install tool (303-1190) into crankshaft front oil seal (see
Figure 1).
Figure 1
5. Tighten centre bolt of tool (303-1190) and withdraw oil seal from timing cover (see Figure 2).
Figure 2
6. Remove seal from special tool.
Installation
1. Clean oil seal aperture in timing cover.
2. Do NOT remove protector from oil seal. 3. Position new oil seal (fitted dry). Install oil seal in timing
cover using tool (303-750) (see Figure 3).
Figure 3
4. Remove crankshaft oil seal protector.
5. Install crankshaft pulley (see Workshop Manual procedure 03.11.CP Pulley Assembly - Crankshaft
Damper - Renew).
6. Lower vehicle on ramp.
7. Battery isolation switch ‘ON’.
Rear Oil Crankshaft Seal-Renew
Removal
1. Remove clutch and flywheel assembly (see Workshop Manual procedure 08.00.AA Clutch and Flywheel
Assembly - Renew).
2. Position tool (303 -1189) to crankshaft flange, screw in alignment bolts (x2) 1.5 turns (only).
3. Use tool and pierce holes (x3) in oil seal through holes in special tool for self-tapping screws
4. Install and tighten self-tapping screws (x3) into oil seal.
5. Tighten centre bolt of tool (303-1189) and withdraw crankshaft oil seal.
6. Remove oil seal from spec ial tool, discard oil seal.
Installation
1. Clean oil seal aperture in cylinder block.
2. Ensure that oil seal protecto r is positioned correctly and
install oil seal onto crankshaft flange.
3. Install tool (303-1189) to crankshaft, position nuts on
tool against oil seal.
Caution
Caution: Make sure the cranks haft front oil seal mating
faces are clean and dry.
Caution
Do not remove the crankshaft front oil seal protector
until the oil seal is correctly installed.
A0311246
A0311246A
Repair Operation Time (ROT)
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Power Conversion (03.11)
Engine (03.00)3-11-36 Workshop Manual May 2007
4. Ensure that oil seal and special are parallel to rear of
engine.
5. To install oil seal, tighten nuts alternately on tool (303- 1189) until oil seal correctly seated.
6. Remove special tool from crankshaft.
7. Check that the oil seal is located correctly.
8. Install clutch and flywheel assembly (see Workshop Manual procedure 08.00.AA Clutch and Flywheel
Assembly - Renew).
Cylinder Block-Renew
Removal
1. Remove cylinder head gasket - engine set (see Workshop Manual procedure 03.01.HW Gasket -
Cylinder Head - Engine Set - Renew With Engine
Removed).
2. Remove crankshaft assembly.
3. Remove pistons and connecting rod assemblies from cylinder block.
4. Remove Torx screws (x4) securing engine oil cooling
valves to cylinder block.
5. Remove engine oil cooling valves (x4).
6. Remove bolts (x5) securing water pump to cylinder block. Remove water pump, discard gasket.
7. Remove cylinder block valley cover.
Installation
1. Clean cylinder block valley cover and mating face on cylinder block.
2. Install cylinder block valley cover.
3. Clean engine oil cooling valves.
4. Install engine oil cooling valves in cylinder block.
5. Install and torque tighten Torx screws (x4).
6. Clean connecting rods and piston assemblies.
7. Correctly position ring gaps on pistons prior to installation.
8. Remove connecting rod bearing caps.
9. Install bearings in connecting rods and bearing caps.
10. Lubricate cylinder bores, pistons and rings with clean engine oil.
11. Install special tools (303-535) to the connecting rod to prevent damage to crankshaft journal.
12. Install crankshaft assembly.
13. Install new gasket, water pump, install and torque tighten bolts (x5). 14. Install cylinder head gasket - engine set (see Workshop
Manual procedure 03.01.HW Gasket - Cylinder Head -
Engine Set - Renew Wi th Engine Removed).
Crankshaft Damper Pulley Assembly-
Renew (with Engine Removed)
Removal
1. Remove engine assembly (see Workshop Manual
procedure 03.00.AA Engine Assembly - Renew).
2. Release drive belt tensioner, release drive belt from idler pulley (see Figure 1).
Figure 1
3. Remove bolt securing drive belt tensioner to engine timing cover, remove tensioner.
4. Remove drive belt from pulleys.
5. Remove bolts (x2), inspection cover to lower crankcase, remove cover.
6. Install tool (303-1185) to restrain flywheel, install and tighten bolts (x2).
7. Install thrust button of tool (303 -1186) in crankshaft,
position tool in pulley, secure with bolts (x2). Tighten
centre bolt, withdraw pulley from crankshaft.
8. Collect crankshaft pulley, locking ring and special tool thrust button.
9. Remove special tool from pulley.
Caution
Alternate nut tightening to correctly seat the crankshaft rear oil seal.
Repair Operation Time (ROT)
WAR NI NG
DO NOT GET USED ENGINE OIL ON YOUR SKIN.
USED ENGINE OIL CAN BE HARMFUL.
Repair Operation Time (ROT)
ItemCode
Crankshaft Damper Pulley Assembly-
Renew 03.11.DP
A030553

Power Conversion (03.11)
Engine (03.00)
May 2007 Workshop Manual 3-11-37
10. Remove and discard O-ring seal from pulley (see Figure
2).
Figure 2
Installation
1. Clean crankshaft pulley, locking ring and mating face on crankshaft.
2. Lubricate and install new O-ring seal in crankshaft pulley.
3. Install crankshaft pulley, locking ring and new pulley bolt.
4. Torque tighten crankshaft pulley bolt. Remove special tool (303-1185) from crankcase.
5. Install inspection cover to lower crankcase, install and tighten bolts (x2).
6. Install drive belt on pulleys.
7. Install drive belt tensioner, install and torque tighten bolt.
8. Release tensioner and install drive belt onto idler pulley.
9. Install engine assembly (see Workshop Manual procedure 03.00.AA Engi ne Assembly - Renew).
Crankshaft Front Oil Seal-Renew (with
Engine Removed
)
Removal
1. Remove crankshaft pulley (see Workshop Manual
procedure 03.11.DP Pulley Assembly - Crankshaft
Damper - Renew With Engine Removed). 2. Install tool (303-1190) into
crankshaft front oil seal (see
Figure 1).
Figure 1
3. Tighten centre bolt of tool (303-1190) and withdraw oil seal from timing cover (see Figure 2).
Figure 2
4. Remove seal from special tool.
Installation
1. Clean oil seal aperture in timing cover.
2. Do NOT remove protector from oil seal.
Repair Operation Time (ROT)
A0311321
Caution
Make sure the crankshaft front oil seal mating faces are clean and dry.
Caution
Do not remove the crankshaft front oil seal protector
until the oil seal is correctly installed.
A0311246
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Power Conversion (03.11)
Engine (03.00)3-11-38 Workshop Manual May 2007
3. Position new oil seal (fitted dry). Install oil seal in timing
cover using tool (303-750) (see Figure 3).
Figure 3
4. Remove crankshaft oil seal protector.
5. Install crankshaft pulle y (see Workshop Manual
procedure 03.11.DP Pulley Assembly - Crankshaft
Damper - Renew With Engine Removed).
Crankshaft Rear Oil Seal-Renew (with
Engine Removed
)
Removal
1. Remove engine assembly (see Workshop Manual
procedure 03.00.AA Engi ne Assembly - Renew).
2. Remove bolts (x2), inspection cover to lower crankcase, remove cover.
3. Install tool (303-1185) to restrain flywheel, install and tighten bolts (x2).
4. Remove bolts (x6), clutch cover to flywheel.
5. Release clutch cover from dowels (x3), remove clutch cover, collect drive plate.
6. Remove and discard bolts (x8), flywheel to crankshaft flange.
7. Remove bolts (x2), collect tool (303-1185).
8. Release flywheel from dowel, remove flywheel.
9. Position tool (303-1189) to crankshaft flange, screw in
alignment bolts (x2) 1.5 turns (only).
10. Use tool and pierce holes (x3) in oil seal through holes in special tool for self-tapping screws
11. Install and tighten self-tapping screws (x3) into oil seal.
12. Tighten centre bolt of tool (303-1189) and withdraw crankshaft oil seal.
13. Remove oil seal from special tool, discard oil seal.
Installation
1. Clean oil seal aperture in cylinder block.
2. Ensure that oil seal protector is positioned correctly and install oil seal onto crankshaft flange.
3. Install tool (303-1189) to crankshaft, position nuts on
tool against oil seal.
4. Ensure that oil seal and special are parallel to rear of engine.
5. To install oil seal, tighten nuts alternately on tool (303- 1189) until oil seal correctly seated.
6. Remove special tool from crankshaft.
7. Check that the oil seal is located correctly.
8. Clean flywheel and mating face on crankshaft.
9. Install flywheel, align to dowel on crankshaft flange.
10. Install new bolts (x8), install tool (303-1185) to restrain flywheel. Torque tighten bolts (x8) in the correct
sequence.
11. Clean clutch cover and drive plate.
12. Install clutch assembly on flywheel, align to dowels (x3).
13. Install bolts (x6), install clutch alignment tool, evenly torque tighten bolts (x6) in a diagonal sequence.
Remove clutch alignment tool.
14. Remove bolts (x2), collect tool (303-1185).
15. Install inspection cover, install and torque tighten bolts (x2).
16. Install engine assembly (see Workshop Manual procedure 03.00.AA Engine Assembly - Renew).
Repair Operation Time (ROT)
A0311247
Caution
Do not use any lubricant on cr ankshaft oil seals or seal
protectors. Make sure all co mponents are clean and dry
Caution
Alternate nut tightening to correctly seat the crankshaft rear oil seal.

Front Suspension (04.01)
Suspension (04.00)
November 2008 Workshop Manual 4-1-1
Suspension (04.00)
Front Suspension (04.01)
Description
Suspension Arms
The upper suspension arm is attached to the body structure.
The lower suspension arm is attached to the front subframe.
Each upper suspension arm has a press-fit ball-joint, and two
interleaved rubber bushes. Two bolts attach the upper
suspension arm to the body structure.
Each lower suspension arm has a press fit ball-joint and
metal-to-rubber bonded bushes which are attached to the
front subframe by two eccentric cam bolts (Camber and
castor settings).
Anti-roll Bar
The anti-roll bar, is attached to the subframe in two positions
by rubber bushes and clamps. The outer ends of the anti-roll
bar are attached to the lower suspension arms by drop links.
The anti-roll bar provides the required stiffness to control
body roll.
Vertical link
The Vertical link (Knuckle Joint) swivels on the upper and
lower suspension arms via ball-joints, and carries the hub, a
unit 3 wheel bearing (including the ABS encoder ring), the
wheel speed sensor, the brake caliper, and the brake disc
and shield. The position of the Vertical link is determined by
the movement of the steering rack, which is connected to
the Vertical link by the steering track rod.
Specifications
Upper Arm Ball Joint
and Bushes
Ball Joint
and Bushes Verticle
Link
Bolts to Body
Lower Arm
Anti-roll Bar Drop Links
Eccentric
Cam Bolts
04-01-003
Torque Figures
DescriptionNmlb. / ft.
Brake dust shield. 9 7
Bearing Assembly to the Vertical
link. 55 41
Vertical Link to the Lower
Suspension Arm. 90 66.5
Vertical Link to the Upper
Suspension Arm. 90 66.5
Track-rod End Lock Nut. 70 52
Vehicle Ride Height Sensor. M8 M522.5
9 17
7
Anti-roll Bar Link Nuts 110 81.5
Anti-roll Bar Mounting Bolts
Torque bolt 1, then bolt 2, then
bolt 1 again (to allow for rubber
compression) 22.5 17
Torque the following suspensi on fixings with the vehicle
at normal ride height
Lower Suspension Arm front
bush to the Subframe M14 185 137
Lower Suspension Arm rear
bush to the Subframe. M12 115 85
Upper Suspension Arm to the
Front Structure 115 85
Spring and Damper Bolts Top Lower22.5
175 17
129.5
Normal ride height 2 x 37.5kg in front seats (37.5kg in
each seat) plus a full fuel tank.

Driveshaft (05.01)
Driveline (05.00)
May 2007 Workshop Manual 5-1-7
6. Manual Only - Bleed clutch hydraulics.
7. Install LH exhaust manifold (see Workshop Manual 09.00.CB Manifold - Exhaust - LH - Renew).
8. Install transaxle (see Workshop Manual07.03.AA Transaxle Assembly - Manual - Remove for Access and
Refit).
9. Lower vehicle on ramp.
10. Connect vehicle battery.
RH/LH Drive Shaft Assembly-Renew
Removal
1. Raise vehicle on ramp.
2. Remove road wheel(s).
3. Remove rear undertray (see Workshop Manual procedure 01.02.PB Undertray - Rear - Renew).
4. With assistance, remove drive shaft nut.
5. Remove and discard Allen bolt s (x6), collect plates (x3),
drive shaft to differential.
6. Release drive shaft from rear hub, remove drive shaft.
Installation
1. Clean drive shaft and mating faces on differential flange and rear hub.
2. Install drive shaft in rear hub, align to differential flange.
3. Apply thread lock to new Allen bolt threads.
4. Clean and install plates (x3), Allen bolts (x6), tighten bolts.
5. Install drive shaft nut. With assistance, tighten nut.
6. Install rear undertray (see Workshop Manual procedure 01.02.PB Undertray - Rear - Renew).
7. Install road wheel(s).
8. Lower vehicle on ramp. Caution
Clutch fluid must not be allowed to contact vehicle paint work. Remove spilt clutch fl uid from the paint work by
rinsing away with running water.
Repair Operation Time (ROT)

Version 6, March 2010 Workshop Manual 6-3-1
Brake System (06.00)
Contents
Front Disc Brake (06.03)........................................ 6-3-2Description ............................................................. 3-2
Specifications.......................................................... 3-2
Maintenance ........................................................... 3-3Front Brake Disc Set - Renew ................................. 3-3
Front Caliper-Renew .............................................. 3-4
Front Pad Kit - Renew ............................................ 3-5
Front Brake Hose Assembly - Renew ...................... 3-5
Rear Disc Brakes (06.04) ....................................... 6-4-1 Description ............................................................. 4-1
Specifications.......................................................... 4-1
Maintenance ........................................................... 4-2Rear Brake Disc Set-Renew .................................... 4-2
RH/LH Rear Caliper-Renew ................................... 4-2
Rear Pad Kit-Renew ............................................... 4-3
Rear Brake Hose Assembly-Renew ......................... 4-4
Hand Brake (06.05) ................ ............................... 6-5-1
Description ............................................................. 5-1
Specifications.......................................................... 5-1
Maintenance ........................................................... 5-2 RH/LH Handbrake Caliper-Re new ......................... 5-2
Handbrake Lever Assembly-Renew ........................ 5-2
Handbrake Pad Set-Renew .................................... 5-2
Handbrake Cable Assembly-Adjust......................... 5-3
Handbrake Cable Assembly-Vehicle Set-Renew ..... 5-3
Brake Actuation System (06.06)............................. 6-6-1 Description ............................................................. 6-1
Tandem Master Cylinder ........................................ 6-1
Specifications.......................................................... 6-1
Maintenance ........................................................... 6-2Pedal Box Assembly - Renew ................................. 6-2
Installation ............................................................. 6-2
RHD-Brake Master Cylinder Assembly-Renew........ 6-2
LHD-Brake Master Cylinder Assembly-Renew ........ 6-3
Clutch Master Cylinder Assembly-Renew ............... 6-3
RH/LH Front Caliper Hose Assembly-Renew .......... 6-4
RH/LH Rear Brake Caliper Tube Assembly-Renew . 6-5
Brake Master Cylinder to Modulator Secondary
Tube Assembly-Renew ........................................... 6-6
Brake Master Cylinder to Modulator Primary
Tube Assembly-Renew ........................................... 6-7
Rear Wheel Brake Front to Rear Tube Assembly
-Renew .................................................................. 6-8
RH Front Caliper to Modulator Tube Assembly
-Renew .................................................................. 6-9
Rear Wheel Brake Tube Assembly-Renew ............ 6-10
Dynamic Stability Control Module-Renew............ 6-11
Power Brake System (06.07) .................................. 6-7-1 Brake Booster ......................................................... 7-1
Emergency Brake Assist .......................................... 7-1
Specifications.......................................................... 7-2
Maintenance ........................................................... 7-2Brake Booster-RHD-Renew.................................... 7-2
Brake Booster-LHD-Renew .................................... 7-2 Brake Fluid Reservoir-Renew ................................. 7-3
Brake Bleeding - AMDS ......................................... 7-3
Brake Master Cylinder and Vacuum Booster
-Renew .................................................................. 7-4
Brake Master Cylinder-Renew ................................ 7-5
Anti-lock Braking System (ABS) (06.09)................. 6-9-1 Dynamic Stability Control ...................................... 9-1Concept ................................................................ 9-1
System Overview ................................................... 9-2
Operation Summary .............................................. 9-2
Traction Control ..................................................... 9-2 Functional Description ........................................... 9-2
Engine Intervention ................................................ 9-3
Brake Intervention ................................................. 9-3
ABS / DSC Circuit .................................................. 9-3
Specifications ......................................................... 9-3 Maintenance ......................................................... 9-4
ABS Modulator - Remove and Install ...................... 9-4