ASTON MARTIN V8 VANTAGE 2010 Workshop Manual

Power Conversion (03.11)
Engine (03.00)
May 2007 Workshop Manual 3-11-19
11. Remove and discard oil scavenge pump gasket (see
Figure 4).
Figure 4
12. Remove oil pump(s) drive sprocket.
13. Disconnect multiplug from oil pressure sensor (see
Figure 5).
Figure 5
14. Disconnect multiplug from engine electric coolant temperature sensor (see Figure 6).
Figure 6
15. Disconnect multiplug from cr ankshaft timing sensor (see
Figure 7).
Figure 7
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Power Conversion (03.11)
Engine (03.00)3-11-20 Workshop Manual May 2007
16.Release harness clips (x6) from sump (see Figure 8).
Figure 8
17. Remove bolts (x4) securing LH and RH HEGO sensor
multiplug brackets to sump (see Figure 9).
Figure 9
18. Disconnect multiplug from A/C compressor. 19. Remove bolts (x4) securing A/C compressor to mounting
bracket. Remove compressor.
20. Remove bolts (x2) securing inlet and outlet oil pipes to sump (see Figure 10).
Figure 10
21. Release both oil pipes together from sump, remove and discard O-ring seals from pipes.
22. Remove Torx bolts (x4) securing A/C compressor mounting bracket to engine bedplate and sump.
Remove bracket (see Figure 11).
Figure 11
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Power Conversion (03.11)
Engine (03.00)
May 2007 Workshop Manual 3-11-21
23. Remove bolts (x16) securing sump to engine bedplate
(see Figure 12).
Figure 12
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 13).
Figure 13
27. Rotate crankshaft clockwis e to access number 1 cylinder
connecting rod bolts. 28. Remove and discard bolts (x
16) securing bearing caps to
connecting rods, remove bearing caps (see Figure 14).
Figure 14
29. Install special tools (303-535) to the connecting rod to prevent damage to crankshaft journal.
30. Carefully push each conne cting rod/piston assembly
upwards and remove from cylinder block.
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 15).
Figure 15
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Caution
Connecting rod bolts are tor que
tightened to yield and
mu st
be replaced.
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Power Conversion (03.11)
Engine (03.00)3-11-22 Workshop Manual May 2007
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 16).
Figure 16
Installation
1. Clean cylinder bores.
2. Use an expander and remove and discard piston rings from pistons.
3. Clean pistons.
4. Install new piston rings, (each set), in cylinder bores to a pre-determined depth and measure ring gaps.
5. Remove each piston ring set from cylinder bores and install on pistons
6. Remove connecting rod bearing caps.
7. Install bearings in connecting rods and bearing caps.
8. Lubricate cylinder bores, pistons and rings with clean
engine oil.
9. Install special tools (303-303-535) to the connecting rod to prevent damage to crankshaft journal.
10. Correctly position ring gaps on pistons prior to
installation. 11. Install piston ring clamp to each piston in turn and install
in its respective cylinder bore. Remove piston ring
clamp (see Figure 17).
Figure 17
12. Lubricate crankshaft journa ls with clean engine oil.
13. Carefully pull each connecting rod into place on each crankshaft journal.
14. Install bearing caps to their relevant connecting rods. Install and torque tighten retaining bolts (x16).
15. Clean windage tray.
16. Install windage tray, install and torque tighten bolts (x8).
17. Clean old sealant from sump flange and engine bedplate.
18. Ensure that sump flange and mating face on engine bedplate are clean and dry.
19. Apply a continuous 3mm diameter bead of RTV sealant to sump flange as recommended.
20. Ensure that there are no gaps in sealant track.
21. Install sump, install and torque tighten bolts (x16) in the correct sequence.
22. Install A/C compressor mounting bracket, install and torque tighten Torx bolts (x4).
23. Lubricate and install new O-ring seals to oil pipes.
24. Install oil pipes in sump, install and torque tighten bolts (x2)
25. Install compressor, install and torque tighten bolts (x4).
26. Connect multiplug to A/C compressor.
27. Install LH and RH HEGO sensor multiplug brackets to
sump. Install and torque tighten bolts (x4).
28. Secure harness clips (x6) in sump.
29. Connect multiplug to crankshaft timing sensor.
30. Connect multiplug to engine electric coolant temperature sensor.
31. Connect multiplug to oil pressure sensor.
Caution
Make sure the piston ring gaps are positioned at
different positions opposite th e thrust side of the piston
before installation.
A0311332
Caution
Install pistons into cylinder block with the

Power Conversion (03.11)
Engine (03.00)
May 2007 Workshop Manual 3-11-23
32. Clean oil scavenge pump and mating face on sump.
33. Install oil pump(s) drive sprocket.
34. Install new oil scavenge pump gasket, align on dowels
(x2).
35. Install chain onto oil scavenge pump sprocket.
36. Install oil scavenge pump, al ign to dowels (x2), Install
and torque tighten bolts (x3).
37. Install chain onto oi l pump drive sprocket.
38. Clean oil pressure pump and mating face on sump.
39. Install new gasket to sump, align to dowels (x2).
40. Position oil pressure pu mp, install chain on pump
sprocket.
41. Install oil pressure pump, align to dowels (x2), Install and
torque tighten bolts (x3).
42. Install chain tensioner, install and torque tighten bolt, remove guide pin.
43. Install crankshaft timing sprocket.
44. Install cylinder head gaskets - engine set (see Workshop Manual procedure 03.01.HW Gasket - Cylinder Head -
Engine Set - Renew With Engine Removed).
Piston Ring-One Piston Set-Renew
Removal
1. Remove cylinder head gaskets - engine set (see Workshop Manual procedure 03.01.HW Gasket -
Cylinder Head - Engine Set - Renew With Engine
Removed).
2. Remove crankshaft timing sprocket from crankshaft.
3. Install guide pin through lower hole on chain tensioner.
4. Remove bolt securing oil pr essure pump chain tensioner
assembly to engine bedplate (see Figure).
Figure
5. Remove tensioner assembly.
6. Remove bolts (x3) securing oil pressure pump to sump.
7. Release chain from oil pressure pump sprocket, remove oil pump. 8. Remove and discard oil pressure pump gasket.
9. Remove bolts (x3) securing
oil scavenge pump to sump
(see Figure 2).
Figure 2
10. Release chain from oil scavenge pump sprocket, remove scavenge pump.
11. Remove and discard oil scavenge pump gasket (see Figure 3).
Figure 3
12. Remove oil pump(s) drive sprocket.
13. Disconnect multiplug from oil pressure sensor (see
Figure 4).
Figure 4
Repair Operation Time (ROT)
WA R N I N G
DO NOT GET USED ENGINE OIL ON YOUR SKIN. USED ENGINE OIL CAN BE HARMFUL.
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Power Conversion (03.11)
Engine (03.00)3-11-24 Workshop Manual May 2007
14.Disconnect multiplug from engine electric coolant
temperature sensor (see Figure 5).
Figure 5
15. Disconnect multiplug from crankshaft timing sensor. (see Figure 6)
Figure 6
16.Release harness clips (x6) from sump (see Figure 7).
Figure 7
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Power Conversion (03.11)
Engine (03.00)
May 2007 Workshop Manual 3-11-25
17. Remove bolts (x4) securing LH and RH HEGO sensor
multiplug brackets to sump (see Figure 8).
Figure 8
18. Disconnect multiplug from A/C compressor.
19. Remove bolts (x4) securing A/C compressor to mounting
bracket. Remove compressor.
20. Remove bolts (x2) securing inlet and outlet oil pipes to sump (see Figure 9).
Figure 9
21. Release both oil pipes toge ther from sump, remove and
discard O-ring seals from pipes. 22. Remove Torx bolts (x4)
securing A/C compressor
mounting bracket to engine bedplate and sump.
Remove bracket (see Figure 10).
Figure 10
23. Remove bolts (x16) securing sump to engine bedplate (see Figure11).
Figure 11
24. Release and remove sump.
25. Remove bolts (x8) securing windage tray to engine bedplate, remove windage tray.
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Power Conversion (03.11)
Engine (03.00)3-11-26 Workshop Manual May 2007
26. Mark bearing caps and connecting rods for correct
installation (see Figure 12).
Figure 12
27. Rotate crankshaft clockwise to access number 1 cylinder
connecting rod bolts.
28. Remove bolts (x2) securing bearing cap to connecting rod, remove bearing cap (see Figure 13).
Figure 13
29. Install special tools (303-535) to the connecting rod to prevent damage to crankshaft journal.
30. Carefully push connecting rod/piston assembly upwards and remove from cylinder bore.
31. Remove special tools from connecting rod.
32. Install bearing cap on connecting rod, 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 14).
Figure 14
34. Note that piston grade number on crown and thick flange on connecting rod faces to front of engine on LH
bank (B) (see Figure5).
Figure 15
Installation
1. Clean cylinder bore.
2. Use an expander and remove piston rings from piston.
3. Install piston rings in cylin der bore to a pre-determined
depth and measure ring gaps.
4. Remove piston ring set from cylinder bore and install on piston.
5. Clean connecting rod.
6. Correctly position ring gaps on piston prior to installation.
7. Remove connecting rod bearing cap.
8. Install bearings in connecting rod and bearing cap.
9. Lubricate cylinder bore, pi ston and rings with clean
engine oil.
Caution
Connecting rod bolts are tor que tightened to yield and
must be replaced.
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Caution
Make sure the piston ring gaps are positioned at
different positions opposite the thrust side of the piston before installation.
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Power Conversion (03.11)
Engine (03.00)
May 2007 Workshop Manual 3-11-27
10. Install special tools (303-535) to the connecting rod to
prevent damage to crankshaft journal.
11. Install piston ring clamp to piston, install piston assembly
in its cylinder bore. Remo ve piston ring clamp (see
Figure 16).
Figure 16
12. Lubricate crankshaft journal with clean engine oil.
13. Carefully pull connecting ro d into place on crankshaft
journal.
14. Install bearing cap to connecting rod. Install and torque tighten retaining bolts (x2).
15. Clean windage tray.
16. Install windage tray, install and torque tighten bolts (x8).
17. Clean old sealant from sump flange and engine bedplate.
18. Ensure that sump flange and mating face on engine bedplate are clean and dry.
19. Apply a continuous 3mm diameter bead of RTV sealant to sump flange as recommended.
20. Ensure that there are no gaps in sealant track.
21. Install sump, install and torque tighten bolts (x16) in the correct sequence.
22. Install A/C compressor mounting bracket, install and torque tighten Torx bolts (x4).
23. Lubricate and install new O-ring seals to oil pipes.
24. Install oil pipes in sump, install and torque tighten bolts (x2)
25. Install compressor, install and torque tighten bolts (x4).
26. Connect multiplug to A/C compressor.
27. Install LH and RH HEGO se nsor multiplug brackets to
sump. Install and torque tighten bolts (x4).
28. Secure harness clips (x6) in sump.
29. Connect multiplug to crankshaft timing sensor.
30. Connect multiplug to engine electric coolant temperature sensor. 31. Connect multiplug to oil pressure sensor.
32. Clean oil scavenge pump and mating face on sump.
33. Install oil pump(s) drive sprocket.
34. Install new oil scavenge pu
mp gasket, align on dowels
(x2).
35. Install chain onto oil scavenge pump sprocket.
36. Install oil scavenge pump, align to dowels (x2), Install and torque tighten bolts (x3).
37. Install chain onto oil pump drive sprocket.
38. Clean oil pressure pump and mating face on sump.
39. Install new gasket to sump, align to dowels (x2).
40. Position oil pressure pump, install chain on pump sprocket.
41. Install oil pressure pump, align to dowels (x2), Install and torque tighten bolts (x3).
42. Install chain tensioner, install and torque tighten bolt, remove guide pin.
43. Install crankshaft timing sprocket.
44. Install cylinder head gaskets - engine set (see Workshop Manual procedure 03.01.HW Gasket - Cylinder Head -
Engine Set - Renew With Engine Removed).Piston Ring Set-Additional-Renew (Each)
Removal
1. Mark bearing cap and connecting rod for correct
installation (see Figure 1).
Figure 1
Caution
Install pistons into cylinder block with the ‘arrow’ on the
piston crown facing to the front of the engine.
Caution
Use only a plastic scraper when removing old sealant
and gaskets from engine components.
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Repair Operation Time (ROT)
WA R N I N G
DO NOT GET USED ENGINE OIL ON YOUR SKIN.
USED ENGINE OIL CAN BE HARMFUL.
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Power Conversion (03.11)
Engine (03.00)3-11-28 Workshop Manual May 2007
2. Remove bolts (x2) securing bearing cap to connecting
rod, remove bearing cap (see Figure 2).
Figure 2
3. Install special tools (303-535) to the connecting rod to prevent damage to crankshaft journal.
4. Carefully push connecting rod/piston assembly upwards and remove from cylinder bore.
5. Remove special tools from connecting rod.
6. Install bearing cap on connecting rod, install and lightly tighten retaining bolts.
Installation
1. Clean cylinder bore.
2. Install piston rings in cylinder bore to a pre-determined depth and measure ring gaps.
3. Remove piston ring set from cylinder bore and install on piston.
4. Clean connecting rod.
5. Correctly position ring gaps on piston prior to installation.
6. Remove connecting rod bearing cap.
7. Install bearings in connecting rod and bearing cap.
8. Lubricate cylinder bore, pi ston and rings with clean
engine oil.
9. Install special tools (303-535) to the connecting rod to prevent damage to crankshaft journal. 10. Install piston ring clamp to piston, install piston assembly
in its cylinder bore. Remove piston ring clamp (see
Figure 3).
Figure 3
11. Lubricate crankshaft jour nal with clean engine oil.
12. Carefully pull connecting rod into place on crankshaft journal.
13. Install bearing cap to connecting rod. Install and torque tighten retaining bolts (x2).
Connecting Rod-Renew (Engine Set)
Removal
1. Remove cylinder head gaskets - engine set (see Workshop Manual procedure 03.01.HW Gasket -
Cylinder Head - Engine Set - Renew With Engine
Removed).
2. Remove crankshaft timing sprocket from crankshaft.
3. Install guide pin through lower hole on chain tensioner.
4. Remove bolt securing oil pressure pump chain tensioner assembly to engine bedplate (see Figure 1).
Figure 1
5. Remove tensioner assembly.
Caution
When using a 'two post' vehicle ramp, remove the
screws that secure the rear section of the wheel arch
liner to body. Hold back the rear section of the wheel
arch liner to correctly position the foot of the vehicle lift.
Caution
Make sure the piston ring gaps are positioned at
different positions opposite th e thrust side of the piston
before installation.
A0311314
Repair Operation Time (ROT)
ItemCode
Connecting Rod-Renew 03.11.CN
WAR NI NG
DO NOT GET USED ENGINE OIL ON YOUR SKIN.
USED ENGINE OIL CAN BE HARMFUL.
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