Timing ASTON MARTIN V8 VANTAGE 2010 Repair Manual

Engine Sealing (03.10)
Engine (03.00)
Issue 5, Janauary 2010 Workshop Manual 3-10-7
13. Remove the 10 bolts evenly and in steps, that attach the left cylinder head to the cylinder block (refer to Figure
3).
Figure 3
14. With the aid of one more person, remove the left cylinder head assembly.
15. Remove and discard the cylinder head gasket.
16. Remove the two Torx bolts, the spacer on the exhaust and the Torx bolt that attaches the right intake and
exhaust camshaft sprockets to the camshafts (refer to
Figure 4).
Figure 4
17. Remove the two bolts that attach the right secondary timing chain tensioner to the cylinder head (refer to
Figure 5).
Figure 5
18. Remove the right camshaft sp rockets complete with the
timing chain and tensioner from the camshafts (refer to
Figure 6).
Figure 6
19. Remove the three bolts that attach tool (303-530) to the cylinder head. Remove the special tool (refer to Figure
7).
Figure 7
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Engine Sealing (03.10)
Engine (03.00)
Issue 5, Janauary 2010 Workshop Manual 3-10-9
8. Install the right exhaust camshaft.
9. Install the five bearing caps in their correct positions.
10. Install the ten bolts and torque tighten them in the sequence specified.
11. Install the Torx bolt that attaches the sprocket to the camshaft.
12. Rotate the camshaft and use feeler gauges to do a check of each valve clearance .
13. Do the procedure again an d install the right intake
camshaft.
14. Remove the Torx bolt that attaches the sprocket.
15. Rotate the right intake and exhaust camshafts until the timing flats on each camshaft face up.
16. Install tool (303-530) onto the right cylinder head to hold the camshafts. Install and tighten the three bolts.
17. Install a new left cylinder he ad gasket. Make sure that it
is correctly engaged on the dowels.
18. With the aid of one more person, install the left cylinder head. Make sure that it is correctly engaged on the
dowels.
19. Install and torque the 12 cylinder head bolts in the correct sequence.
20. Lubricate the left exhaust camshaft journals, camshaft lobes, bearing surfaces on the cylinder head and the
bearing caps with clean engine oil.
21. Install left exhaust camshaft.
22. Install the five bearing caps in their correct positions.
23. Install the ten bolts and torque in the sequence specified.
24. Install the Torx bolt that attaches the sprocket to the left exhaust camshaft.
25. Rotate the left exhaust cam shaft as necessary and use
feeler guages to do a check of each valve clearance.
26. Remove the Torx bolt that attaches the sprocket.
27. Install the left intake camshaft (refer to Workshop Manual procedure 03.09.AV Camshaft - Intake - LH -
Renew).
28. Install the timing chain tensioning tool (303-532) into the right exhaust camshaft sprocket.
29. Apply a force to the tool (303-532) in a counterclockwise direction to hold the sprocket and
torque the right sprocket Torx bolts.
30. Remove the special tool.
31. Connect the electrical conne ctors to the left and right
camshaft timing sensors.
32. Connect the electrical connector to each of the two left and two right knock sensors. 33. Install SAI pump and bracket assembly (refer to
Workshop Manual procedure 03.08.DB Pump and
Bracket Assembly - Secondary Air Injection - Renew).
34. Clean the left exhaust manifold.
35. Install a new gasket for the left exhaust manifold .
36. Install the left exhaust manifold.
37. Install and torque tighten the eight nuts.
38. Install the left front wheel arch liner (refer to Workshop
Manual procedure 01.02.FB Wheel Arch Liner - Front -
LH - Renew).
39. Install the right exhaust manifold (refer to Workshop Manual procedure 09.00.CC Gasket - Exhaust Manifold
- right - Renew).
Right Side Cam Cover - Remove and
Install
Removal
1. Disconnect the battery earth cable.
2. Remove the front crush brace. (Refer to procedure
01.01.LC - Front Crush Brace)
3. Remove the right side fr ont crush bar for the body
reinforcement. (Refer to procedure 01.01.AB - Right
Side Front Crush Bar for the Body Reinforcement)
4. Remove the breather pipe from the cam cover.
5. Install applicable caps to seal the open ports.
6. Remove the ignition coil cover.
7. Disconnect the electrical connector from each of the four ignition coils.
8. Disconnect the electrical connector from the Variable Valve Timing (VVT) solenoid.
9. Release the fir tree clip that attaches the wiring harness for the ignition coils.
10. Move the wiring harness for the ignition coils away.
11. Release the wiring harness for the injectors from the mounts.
12. Cut and remove the three cable ties that attach the rear of the wiring harness for the injectors.
13. Remove the screw that attaches the purge pipe P-clip to the cam cover.
14. Move the purge-pipe P-clip away.
15. Release the purge pipe and heater pipe from the two clips on the wiring harness bracket.
16. Remove the two nuts and two screws that attach the front bracket for the wiring harness.
17. Remove the three screws that attach the rear bracket for
the wiring harness.
18. Remove the rear bracket for the wiring harness.
19. Remove the front bracket for the wiring harness.
WA R N I N G
DO NOT GET USED ENGINE OIL ON YOUR SKIN. USED ENGINE OIL CAN BE HARMFUL.
Caution
Gradually tighten one bolt and then the next to correctly
install the camshaft bearing ca ps in the step that follows.
Repair Operation Time (ROT)

Engine Sealing (03.10)
Engine (03.00)
Issue 5, Janauary 2010 Workshop Manual 3-10-11
Removal
1. Remove the left side cam cover (Refer to ’Left Side Cam Cover - Remove and Install’, page 3-10-4).
2. Remove the right side cam cover (Refer to ’Right Side Cam Cover - Remove and Install’, page 3-10-9).
Install
1. Install the left side cam cover (Refer to ’Left Side Cam Cover - Remove and Install’, page 3-10-4).
2. Install the right side cam cover (Refer to ’Right Side Cam Cover - Remove and Install’, page 3-10-9).
Engine Timing Cover-Renew (with Engine
Removed
)
Removal
1. Remove the engine assembly (refer Workshop Manual procedure 03.00.AA Engi ne Assembly - Renew).
2. Position drain container.
3. Remove the drain plug and drain the oil from the sump.
4. Remove the left cam cover (Refer to ’Left Side Cam Cover - Remove and Install’, page 3-10-4).
5. Remove the right cam cover (Refer to ’Right Side Cam Cover - Remove and Install’, page 3-10-9).
6. Release the hose clips and disconnect the two coolant hoses from the coolant manifold.
7. Release the hose clip and di sconnect the hose from the
oil separator.
8. Remove the four Torx bolts that attach the coolant manifold to cylinder heads (refer to Figure 1).
Figure 1
9. Release the coolant mani fold from coolant pipe,
disconnect the temperature sensor multiplug.
10. Remove the coolant manifold.
11. Remove and discard the two O-rings from the coolant manifold. 12. Loosen the three water pump pulley bolts (refer to
Figure 2).
Figure 2
13. Use an applicable socket bar to release the auxiliary
drive belt tensioner.
14. Remove the drive belt.
15. Remove the three bolts and remove the water pump pulley.
16. Remove the bolt that attaches the auxiliary drive belt tensioner.
17. Remove the tensioner (refer to Figure 3).
Figure 3
18. Remove the two bolts that attach the inspection cover to the lower crankcase. Remove the cover.
19. Install tool (303-1185) to hold flywheel. Install and tighten the two bolts .
20. Install the thrust button of tool (303 -1186) into the crankshaft.
21. Put the tool in position in the pulley. Attach the tool with the two bolts. Tighten the centre bolt and remove
the pulley from the crankshaft.
22. Collect the crankshaft pulley, locking ring and the special tool thrust button.
23. Remove the special tool from the pulley.
24. Remove and discard the O-ring seal from pulley.
25. Remove the bolt that attaches the alternator idler pulley.
Repair Operation Time (ROT)
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Engine Sealing (03.10)
Engine (03.00)3-10-12 Workshop Manual Issue 5, Janauary 2010
26. Remove the pulley (refer to Figure 4).
Figure 4
27. Remove the bolt that attaches the A/C compressor idler pulley. Remove the pulley (refer to Figure 5).
Figure 5
28. Position the drain tray.
29. Remove the oil filter.
30. Release the oil separator drain tube from the timing cover (refer to Figure 6).
Figure 6
31. Release the clip for the oil separator drain tube from the bracket. 32. Release the terminal cover on the alternator. Remove
the nut that attaches the battery cable to the alternator.
(refer to Figure 7).
Figure 7
33. Disconnect the electrical connector from the alternator.
34. Remove the bolt and the nut and bolt that attach the alternator.
35. Remove the alternator.
36. Remove the three Torx bolts that attach the alternator mounting bracket to cylinder block. Remove the bracket
(refer to Figure 8).
Figure 8
37. Remove the three bolts that attach the PAS pump to mounting bracket. Move the pump away.
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Engine Sealing (03.10)
Engine (03.00)
Issue 5, Janauary 2010 Workshop Manual 3-10-13
38. Remove the four Torx bolts that attach the PAS pump mounting bracket to the cylinder block. Remove the
bracket (refer to Figure 9).
Figure 9
39. Remove the 27 bolts that attach the timing cover to the engine. Collect the bracet for the oil separator drain
tube. Remove the timing cover.
40. Remove the outer and inner rubber seals from the timing cover (refer to Figure0).
Figure0
41. Remove the front crankshaft oil seal from timing cover.
Installation
1. Clean the timing cover and mating face on engine.
2. Install the inner and outer seals into timing cover.
3. Apply 3mm x 12mm beads of sealant to the eight joints
on the engine.
4. Install the timing cover. Put the oil separator drain tube bracket in position. Install the 27 bolts and torque the
bolts in the specified sequence. 5. Using tool (303-750), instal
l front crankshaft oil seal.
Remove special tool and seal protector.
6. Clean crankshaft pulley and mating face on crankshaft.
7. Lubricate and install new O-ring seal in crankshaft pulley.
8. Install crankshaft pulley, locking ring and new pulley bolt.
9. Torque tighten crankshaft pulley bolt. Remove special tool (303-1185) from crankcase.
10. Install inspection cover to lower crankcase, install and tighten bolts (x2).
11. Install PAS pump mounting bracket, install and torque tighten Torx bolts (x4).
12. Install PAS pump, install and torque tighten bolts (x3).
13. Install alternator mounting bracket, install and torque tighten Torx bolts (x3).
14. Install alternator, install bolt and nut/bolt and torque tighten
15. Connect battery cable, install and torque tighten nut, secure cover. Connect multiplug.
16. Lubricate seal, install new oil filter.
17. Install oil separator drai n tube clip in bracket.
18. Install oil separator drain tube to timing cover.
19. Install A/C compressor idler pulley, torque tighten bolt.
20. Install alternator idler pulley, torque tighten bolt.
21. Install auxiliary drive belt te nsioner, torque tighten bolt.
22. Install water pump pulley, install bolts (x3).
23. Using a suitable socket ba r, release auxiliary drive belt
tensioner, install drive belt.
24. Torque tighten water pump pulley bolts (x3).
25. Clean coolant manifold and mating faces on cylinder heads.
26. Install new O-ring seals (x2) to coolant manifold.
27. Position coolant manifold, connect temperature sensor
multiplug, install coolant pipe in manifold.
28. Install and torque tighten Torx bolts (x4) that attach the coolant manifold to cylinder heads.
29. Connect coolant hoses (x3) to coolant manifold and
secure clips.
30. Connect engine breather to oil separator.
31. Clean left and right cam covers.
32. Install the right cam cover (Refer to ’Right Side Cam Cover - Remove and Install’, page 3-10-9).
33. Install left cam cover (Refer to ’Left Side Cam Cover -
Remove and Install’, page 3-10-4).
34. Install the engine assembly (refer to Workshop Manual procedure 03.00.AA Engine Assembly - Renew).
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.
If you do, the oil seal can be damaged.
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Caution
The bolt thread in the cran kshaft must be cleaned out
before a new crankshaft pulley retaining bolt is installed.
Note: Check the crankshaft pulley and locking ring for damage.

Engine Sealing (03.10)
Engine (03.00)3-10-14 Workshop Manual Issue 5, Janauary 2010
John Guest Cartridge in the Engine
Timing Cover - Repair
Removal
1. Open the bonnet.
2. Raise the vehicle and make it safe.
3. On Roadster models, remove the front undertray (Refer
to ’Centre Undertray - Remove and Install (Roadster
Only)’, page 1-2-1).
4. Put an approved container under the front cover to collect oil.
5. Disconnect the oil drain pipe from the John Guest
cartridge.
6. Let the oil drain.
7. Use a trim tool as a lever to remove the plastic collet from the cartridge.
8. Remove and discard the O-ring from the cartridge.
9. Clean all unwanted oil from the cartridge.
Install
1. Apply a layer of oil to the new O-ring .
2. Carefully install the new O- ring in the cartridge. Make
sure that the O-ring is in the correct position against the
shoulder of the cartridge.
3. Install the new plastic collet into the cartridge.
4. Connect the oil pipe into the cartridge.
5. Clean all unwanted oil from the area around the cartridge.
6. Remove the container of drained oil.
7. On Roadster models, install the front undertray (Refer to ’Centre Undertray - Remove and Install (Roadster
Only)’, page 1-2-1).
8. Lower the vehicle.
9. Remove the cap from the oil tank.
10. Add oil to the oil tank to the correct level.
11. Install the cap on the oil tank.
12. Start and operate the engine for approximately five minutes.
13. Stop the engine.
14. Wait five minutes for the oil to drain back to the sump.
15. Do a check of the oil le vel. Add oil if necessary. 16. Install the oil tank cap.
17. Close the bonnet.
Repair Operation Time (ROT)

Power Conversion (03.11)
Engine (03.00)
May 2007 Workshop Manual 3-11-7
27. Clean flywheel and mating face on crankshaft.
28. Install flywheel, align to dowel on crankshaft flange.
29. Install new bolts (x8), install tool (303-1185) to restrain
flywheel. Torque tighten bolts (x8) in the correct
sequence.
30. Clean clutch cover and drive plate.
31. Install clutch assembly on fl ywheel, align to dowels (x3).
32. Install bolts (x6), install clutch alignment tool, evenly torque tighten bolts (x6) in a diagonal sequence.
Remove clutch alignment tool.
33. Remove bolts (x2), collect tool (303-1185).
34. Install inspection cover, install and torque tighten bolts (x2).
35. Install engine sump (see Workshop Manual procedure 03.02.CN Pan - Oil Sump - Remove and Reseal With
Engine Removed).
Piston-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 pr essure pump chain tensioner
assembly to engine bedplate (see Figure 1).
Figure 1
5. Remove tensioner assembly (see Figure 2). 6. Remove bolts (x3) securing oil pressure pump to sump
(see Figure 3).
Figure 3
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 4).
Figure 4
10. Release chain from oil scavenge pump sprocket, remove scavenge pump.
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)3-11-8 Workshop Manual May 2007
11.Remove and discard oil scavenge pump gasket (see
Figure 5).
Figure 5
12. Remove oil pump(s) drive sprocket.
13. Disconnect multiplug from oil pressure sensor (see Figure 6).
Figure 6
14.Disconnect multiplug from engine electric coolant temperature sensor (see Figure 7).
Figure 7
15. Disconnect multiplug from cr ankshaft timing sensor (see
Figure 8).
Figure 8
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Power Conversion (03.11)
Engine (03.00)3-11-12 Workshop Manual May 2007
12. 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
13. Lubricate crankshaft journa ls with clean engine oil.
14. Carefully pull each connecting rod into place on each crankshaft journal.
15. Install bearing caps to their relevant connecting rods. Install and torque tighten retaining bolts (x16).
16. Clean windage tray.
17. Install windage tray, install and torque tighten bolts (x8).
18. Clean old sealant from sump flange and engine bedplate.
19. Ensure that sump flange and mating face on engine bedplate are clean and dry.
20. Apply a continuous 3mm diameter bead of RTV sealant to sump flange as recommended.
21. Ensure that there are no gaps in sealant track.
22. Install sump, install and torque tighten bolts (x16) in the correct sequence.
23. Install A/C compressor mounting bracket, install and torque tighten Torx bolts (x4).
24. Lubricate and install new O-ring seals to oil pipes.
25. Install oil pipes in sump, install and torque tighten bolts (x2)
26. Install compressor, install and torque tighten bolts (x4).
27. Connect multiplug to A/C compressor.
28. Install LH and RH HEGO sensor multiplug brackets to sump. Install and torque tighten bolts (x4).
29. Secure harness clips (x6) in sump.
30. Connect multiplug to crankshaft timing sensor.
31. Connect multiplug to engine electric coolant temperature sensor.
32. Connect multiplug to oil pressure sensor.
33. Clean oil scavenge pump and mating face on sump.
34. Install oil pump(s) drive sprocket. 35. Install new oil scavenge pump gasket, align on dowels
(x2).
36. Install chain onto oil scavenge pump sprocket.
37. Install oil scavenge pump, align to dowels (x2), Install
and torque tighten bolts (x3).
38. Install chain onto oil pump drive sprocket.
39. Clean oil pressure pump and mating face on sump.
40. Install new gasket to sump, align to dowels (x2).
41. Position oil pressure pu mp, install chain on pump
sprocket.
42. Install oil pressure pump, align to dowels (x2), Install and
torque tighten bolts (x3).
43. Install chain tensioner, install and torque tighten bolt, remove guide pin.
44. Install crankshaft timing sprocket.
45. Install cylinder head gaskets - engine set (see Workshop Manual procedure 03.01.HW Gasket - Cylinder Head -
Engine Set - Renew Wi th Engine Removed).
Piston-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 pressure pump chain tensioner assembly to engine bedplate (see Figure 1).
Figure 1
Caution
When assembling connecting rods and connecting rod
bearing caps it is imperative that bearing slots and tangs
be located on the same side of the connecting rods.
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Repair Operation Time (ROT)
ItemCode
Piston-Renew 03.11.CH
WAR NI NG
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)3-11-14 Workshop Manual May 2007
15. Disconnect multiplug from crankshaft timing sensor (see
Figure 7).
Figure 7
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 (see Figure 10).
Figure 10
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