BATTERY SYSTEM ASTON MARTIN V8 VANTAGE 2010 Repair Manual

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).

Accessory Drive System (03.05)
Issue 4, November 2008Workshop Manual 3-5-1
Engine (03.00)
Accessory Drive System (03.05)
Description
Remove
1. Set the battery isolation switch to ‘OFF’.
2. Release the three clips and remove the throttle body
duct for access..
3. Disconnect the two ‘quickfit’ breather pipe connections from the air cleaner duct.
Torque Figures
DescriptionNmlb/ft
Belt Tensioner 34-46 25.1-
34
Idler Pulleys 34-46 25.1-
34
Repair Operation Time (ROT)
Repair Operation Time (ROT)

Accessory Drive System (03.05)
3-5-2Workshop ManualIssue 4, November 2008
4. Release the tensioner and remove the belt from the idler
(see Figure 1).
Figure 1
5. Remove the bolt that attaches the tensioner to the engine and remove.
Install
1. Install tensioner to engine (bolt x1) (torque).
2. Release tensioner and slip belt on idler.
3. Install throttle body duct.
4. Connect breather pipe quickf its (x2) to air cleaner duct.
5. Battery isolation switch ‘ON’.
Idler Pulley-Renew
Removal
1. Set the battery isolation switch to ‘OFF’.
2. Release the three clips and remove the throttle body duct for access.
3. Disconnect the two ‘quick-fit’ breather pipe connectors from the air cleaner duct.
4. Release the tensioner and remove the belt from the idler. 5. Remove the bolt (2) that attaches the idler (1) to the
engine (refer to Figure 1)..
Figure 1
6. Remove the idler.
Install
1. Install idler to engine (bolt x1) (torque).
2. Release tensioner and slip belt on idler.
3. Install throttle body duct.
4. Connect breather pipe quickfits (x2) to air cleaner duct.
5. Battery isolation switch ‘ON’.
Engine Drive Belt Idler Assembly-Renew
Removal
1. Set the battery isolation switch to ‘OFF’.
2. Release the three clips and remove the throttle body duct for access.
3. Disconnect the two ‘quick-fit’ breather pipe connectors from the air cleaner duct.
Repair Operation Time (ROT)
A030553
Repair Operation Time (ROT)
ItemCode
Engine Drive Belt Idler Assembly-
Renew 03.05.BG

Accessory Drive System (03.05)
Issue 4, November 2008Workshop Manual 3-5-3
4. Release the tensioner and remove the belt from the idler
(see Figure 1).
Figure 1
5. Remove the bolt that attaches the idler to the engine.
6. Remove the idler.
Installation
1. Put the idler in position on the engine.
2. Install and torque the bolt that attaches the idler.
3. Release the tensioner and put the belt on the idler.
4. Install the duct for the throttle body.
5. Connect the two ‘quick-fit’ connectors for the breather pipes to the air cleaner duct.
6. Set the battery isolation switch to ‘ON’.

Engine Cranking System (03.06)
May 2007Workshop Manual 3-6-1
Engine (03.00)
Engine Cranking System (03.06)
Maintenance
Removal
1. Remove RH exhaust manifold (see Workshop Manual
procedure 09.00.CA Manifold - Exhaust - RH - Renew).
2. Switch battery isolation switch ‘OFF’.
3. Remove battery cable from starter motor.
4. Disconnect solenoid multiplug from starter motor (see Figure 1).
Figure 1
5. Remove starter motor bolts (x2) (see Figure 2).
Figure 2
Installation
1. Install starter motor bolts (x2).
2. Connect solenoid multiplug to starter motor.
3. Install battery cable from starter motor.
4. Switch battery isolation switch ‘ON’. 5. Install RH exhaust manifold (see Workshop Manual
procedure 09.00.CA Manifold - Exhaust - RH - Renew).
Repair Operation Time (ROT)

Engine Sealing (03.10)
Engine (03.00)3-10-4 Workshop Manual Issue 5, Janauary 2010
20. Put the alternator in position.
21. Install the M8 bolt that attaches the top of the alternator.
22. Install the M10 nut and bolt that attaches the bottom of the alternator.
23. Torque tighten the alternator attachment bolts.
24. Connect the battery cable to the alternator.
25. Install and torque the nut that attaches the battery cable.
26. Install the cover for the cable connection.
27. Connect the electrical connector to the alternator.
28. Apply new engine oil to the seal on a new oil filter.
29. Install the new oil filter.
30. Install the drain tube for the oil separator into the clip in the bracket.
31. Install the drain tube for the oil separator into timing cover.
32. Install the idler pulley for the air conditioning compressor.
33. Install and torque the M10 bolt that attaches the idler pulley.
34. Install the alternator idler pulley.
35. Install and torque the M10 bolt that attaches the idler pulley.
36. Install the auxiliary drive belt tensioner.
37. Install and torque the M10 bolt that attaches the tensioner.
38. Put the water pump pulley in position.
39. Install the three M6 bolts that attach the water pump pulley.
40. Turn the auxiliary drive be lt tensioner until you can
install the drive belt.
41. Torque tighten the three M6 water pump pulley bolts.
42. Clean the coolant manifold and the mating faces on the cylinder heads.
43. Install two new O-ring seals into the coolant manifold.
44. Put the coolant manifold in position.
45. Connect the electrical connector for the temperature sensor.
46. Install the coolant pipe in the manifold.
47. Install and torque tighten the four M6 Torx bolts that attach the coolant manifold to the cylinder heads.
48. Connect the three coolant hoses to the coolant manifold and install the hose clips.
49. Connect the engine breather to the oil separator.
50. Clean the left and right cam covers.
51. Install the inner and outer seals on the left cam cover.
52. Install the left cam cover (Refer to ’Left Side Cam Cover - Remove and Install’, page 3-10-4).
53. Install the inner and outer seals on the right cam cover.
54. Install the right cam cover (Refer to ’Right Side Cam Cover - Remove and Install’, page 3-10-9).
55. Install the front subframe (refer to Workshop Manual procedure 02.01.BA Subframe Assembly - Front -
Remove for Access and Refit). 56. Install the oil tank assembly
(refer to Workshop Manual
procedure 03.02.CA Tank Assembly - Oil Cooler -
Renew).
57. Fill the cooling system (refer to Workshop Manual procedure 03.03.AD Coolant - Drain and Refill).
Left 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 left side front crush bar for the body reinforcement. (Refer to procedure 01.01.AC - Left Side
Front Crush Bar for the Body Reinforcement).
4. Disconnect the breather pi pes from the cam cover and
the oil tank Y-piece.
5. Use 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. Release the purge pipe an d heater pipe from the two
clips on the wiring harness bracket.
14. Remove the two nuts and three screws that attach the front bracket for the wiring harness.
15. Remove the three screws that attach the rear bracket for the wiring harness.
16. Cut and remove the four cable ties that attach the rear
of the wiring harness to the front bracket.
17. Remove the rear bracket for the wiring harness.
18. Remove the front bracket for the wiring harness.
19. Remove the screw that attaches each of the four ignition coils.
20. Remove the four ignition coils.
21. Remove the 14 screws that attach the cam cover to the
engine.
Repair Operation Time (ROT)
ItemCode
Left Side Cam Cover - Remove and
Install 03.10.AS
Note: When you remo ve the cam cover attachment bolts in
the step that follows , record their installed positions in the
cam cover.

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)

Driveshaft (05.01)
Driveline (05.00)5-1-2 Workshop Manual May 2007
Driveline (05.00)
Driveshaft (05.01)
Description
The driveshaft consists of a torque tube
assembly, incorporating a carbon fibre
propshaft, transferring engine power to
the gearbox.
The torque tube acts as a structural
support between the engine and
transmission through the powertrain
maintaining NVH (Noise, Vibration &
Harshness) and crash worthiness.
Specifications
Maintenance
Propeller Shaft-Renew
Removal
1. Disconnect vehicle battery.
2. Raise vehicle on ramp.
3. Remove transaxle (see Workshop Manual procedure 07.03.AA Manual or 07.03.BA Sportshift - Transaxle
Assembly - Remove for Access and Refit).
4. Lower lifter supporting torque tube.
5. Remove large circlip and with assistance, remove propshaft from torque tube
Installation
1. Clean propeller shaft assembly, circlip and mating faces.
2. With assistance, install propshaft into torque tube, install circlip. 3. Raise lifter supporting torque tube to enable installation
of transaxle.
4. Install transaxle (see Workshop Manual procedure 07.03.AA Manual or 07.03.BA Sportshift - Transaxle
Assembly - Remove for Access and Refit).
5. Lower vehicle on ramp.
6. Connect vehicle battery.
Propshaft Cam Sensor-Sportshift-Renew-
Sportshift Only
Removal
1. Disconnect vehicle battery.
2. Raise vehicle on ramp.
3. Remove exhaust system (see Workshop Manual procedure 09.00.NB Exhaust System - Excluding
Manifold/DownPipes - Renew).
4. Disconnect multiplug between propshaft speed sensor and transmission harness.
Torque Figures
DescriptionNm.lb. / ft.
Torque Tube (front) M10 43-57 (Nominal 50.5 ±15%)32-42.5
Torque Tube (rear) 43-57 (Nominal 50.5 ±15%)32-42.5
Exhaust Manifold 18-22 13.5-16.5
Starter Motor 50 37
Repair Operation Time (ROT)
Repair Operation Time (ROT)
ItemCode
Propshaft Cam Sensor-Sportshift-
Renew 05.01.AC
Warning
Always disconnect the battery earth (- ve) terminal first.
Warning
When raising the vehicle on a ‘two post’ ramp, ensure
that the rear end of the vehi cle is securely strapped to
the ramp. Failure to strap th e rear of the vehicle down
may lead to the vehicl e falling off the ramp.
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.