coolant ASTON MARTIN V8 VANTAGE 2010 Repair Manual
[x] Cancel search | Manufacturer: ASTON MARTIN, Model Year: 2010, Model line: V8 VANTAGE, Model: ASTON MARTIN V8 VANTAGE 2010Pages: 947, PDF Size: 43.21 MB
Page 503 of 947
Power Brake System (06.07)
Brake System (06.00)
May 2007 Workshop Manual 6-7-3
Installation
1. Install booster assembly.
2. Connect brake pipes to master cylinder.
3. Install bolts (x2) clutch pipe bracket.
4. Connect clutch reservoir feed pipe.
5. Connect multiplugs (x4).
6. Install vacuum hose.
7. Install expansion tank asid e (bolt x1, nut x1, hose clips
x2, multiplug x1).
8. Install corner cross brace (torque) (only fully tighten
when vehicle on level floor).
9. Install servo retaining nuts (x4) (torque).
10. Install clevis pin and clip.
11. Bleed Brakes (see Workshop Manual procedure 06.06.AD Pad Kit - Manual Brake and Clutch Pedal -
Renew).
12. Top-up coolant.
Brake Fluid Reservoir-Renew
Removal
1. Remove corner cross brace.
2. Move expansion tank aside for access (bolt x1, nut x1, hose clips x2, multiplug x1).
3. Disconnect clutch reservoir feed pipe.
4. Disconnect multiplugs (x2). 5. Disconnect brake pipes from master cylinder (move
aside).
6. Remove reservoir holding screw for access to master cylinder retaining nut.
7. Remove master cylinder from booster (nuts x2).
8. Remove reservoir from master cylinder.
Installation
1. Fit new seals and install reservoir to master cylinder.
2. Install master cylinder to booster (nuts x2).
3. Install reservoir holding screw for access to master cylinder retaining nut
4. Connect brake pipes to master cylinder.
5. Connect clutch reservoir feed pipe.
6. Connect multiplugs (x2).
7. Install expansion tank aside (bolt x1, nut x1, hose clips x2, multiplug x1).
8. Install corner cross brace (torque) (only fully tighten
when vehicle on level floor).
9. Bleed Brakes (see Workshop Manual procedure 06.07.DD Brake Hydraulic System - Flush/Refill/Bleed).
10. Top-up coolant.
Brake Bleeding - AMDS
Use the AMDS to bleed the brakes if you are bleeding the
brake system after you replaced a major component, for
example: a modulator or a mast er cylinder or when filling
from empty.
If you are bleeding a caliper, you can use a manual brake-
bleed procedure.
1. Connect the AMDS.
Repair Operation Time (ROT)
Repair Operation Time (ROT)
Page 505 of 947
Power Brake System (06.07)
Brake System (06.00)
May 2007 Workshop Manual 6-7-5
12. Top-up coolant.
Brake Master Cylinder-Renew
Removal
1. Remove corner cross brace.
2. Move expansion tank aside for access (bolt x1, nut x1, hose clips x2, multiplug x1).
3. Disconnect clutch reservoir feed pipe.
4. Disconnect multiplugs (x2).
5. Disconnect brake pipes from master cylinder (move aside).
6. Remove reservoir holding screw for access to master cylinder retaining nut.
7. Remove master cylinder from booster (nuts x2).
Installation
1. On new master cylinder - Remove reservoir holding screw for access to master cylinder retaining nut
2. Install master cylinder to booster (nuts x2).
3. Install reservoir holding screw for access to master cylinder retaining nut
4. Connect brake pipes to master cylinder.
5. Connect clutch reservoir feed pipe.
6. Connect multiplugs (x2).
7. Install expansion tank asid e (bolt x1, nut x1, hose clips
x2, multiplug x1). 8. Install corner cross brace
(torque) (only fully tighten
when vehicle on level floor).
9. Bleed Brakes (see Workshop Manual procedure 006.07.DD Brake Hydraulic System - Flush/Refill/
Bleed).
10. Top-up coolant.
Repair Operation Time (ROT)
Page 518 of 947
Manual Transmission (07.03)
Transmission (07.00)7-3-2 Workshop Manual Issue 5, January 2010
Specifications Maintenance
Transaxle Assembly - Remove for Access
and Install
Removal
1. Disconnect the battery ground cable.
2. Remove the rear undertray (refer to Workshop Manual procedure 01.02.PB - Rear Undertray).
3. Raise the vehicle and install straps to hold it to the lift (refer to Figure 1).
Figure 1
Type
Graziano AM803T transaxle with:
• Integrated Shifter Bellcrack System (Cable Operated)
• Integrated Reverse Switch
• Plate Type Limited Slip Differential
Synchronisers
Triple Cone Syncros on 1st and 2nd, double cone on all
other gears incl. reverse.
Lubrication
Pressure fed system with integrated pump driven by the
input shaft. Filter (filter is serviceable item).
Transaxle Oil
Shell Transaxle 75W/90 (very important that this is the
transaxle type, Do not use Shell Spirax 75W90)
Transaxle Quantity.
Coolant System Quantity. 4 ltr (7 pt / 4.2 US qts)
0.5 ltr (0.9 pt / 0.53 US qts)
Transaxle + Coolant
Quantity 4.5 ltr (7.9 pt / 4.6 US qts)
Gear Ratios
1st 2nd 3rd 4th 5th 6th
3.15:1 1.95:1 1.44:1 1.15:1 0.94:1 0.77:1 (upto VIN
C00525)
0.76:1 (VIN
C00526
Onwards)
Reverse
2.39:1
Differential Locking Ratio
10% Drive, 30% Coast
Torque Figures
DescriptionNm.lb. / ft.
Sump plug 49 36.5
LH Output shaft housing 10 7.5
Halfshaft 70 52
Differential Cover 35 26
Repair Operation Time (ROT)
ItemCode
Transaxle Assembly-Remove for
Access/Refit 07.03.AA
WAR NI NG
WHEN YOU LIFT THE VEHICLE ON A 'TWO POST' LIFT MAKE SURE THAT YOU USE A STRAP TO HOLD THE REAR END OF THE VEHICLE TO THE RAMP. IF YOU
DO NOT, THE VEHICLE CAN FALL OFF THE RAMP AND CAUSE PERSONAL INJURY OR DEATH.
WAR NI NG
THE EXHAUST SYSTEM WILL BE VERY HOT AFTER
OPERATION. LET THE EXHA UST COOL BEFORE YOU
DO WORK. IF YOU DO NO T, PESONAL INJURY CAN
OCCUR.
Page 605 of 947
Power Steering (11.02)
Steering (11.00)11-2-2 Workshop Manual Issue 5, January 2010
Maintenance
Power Steering System - Bleed
Procedure
1. Do a check of the fluid level in the PAS fluid reservoir. Add fluid if necessary.
2. Start the engine and let it idle for 20 seconds.
3. Operate the steering fully to the left and then the right through three cycles.
4. Stop the engine.
5. Wait for five minutes then do a check of the fluid level in the PAS fluid reservoir again.
6. Add fluid if necessary.
7. Install the PAS fluid reservoir cap.
Power Steering Pump-Renew
Removal
1. Remove A/C compressor (see Workshop Manual procedure 03.05.BE Compre ssor - Air Conditioning -
Renew).
2. Coolant drain (see Workshop Manual procedure 03.03.AD Coolant - Drain & Refill).
3. Remove PAS fluid from reservoir.
4. Disconnect HP union from PAS pump pipe.
5. Remove bolt P-clip suction hose to body.
6. Remove bolt (x1) HP pump pipe to engine.
7. Remove bolts (x3) PAS pump to engine.
8. Disconnect bottom hose and move aside.
9. Unclip (x1) harness from cylinder head for access.
10. Manouvre pump forward and up.
11. Disconnect suction hose (cut off clip) and remove pump.
12. Remove HP union pipe from pump (mark position on
pump).
Installation
1. Install HP union pipe to pump (align correctly), fit new O-ring.
2. Install pump to vehicle connect suction pipe to PAS pump, align timing marks and fit new clip.
3. Manouvre pump into position.
4. Install bolts (x3) PAS pump to engine (torque).
5. Install bolt (x1) HP pump pipe to engine (torque).
6. Connect bottom hose.
7. Clip (x1) harness from cylinder head for access. 8. Install bolt P-clip suction hose to body (torque).
9. Connect HP union to PAS pump pipe, replace O-ring
(torque).
10. Coolant refill (see Workshop Manual procedure 03.03.AD Coolant - Drain & Refill).
11. Install A/C compressor (see Workshop Manual procedure 03.05.BE Compre ssor - Air Conditioning -
Renew).
12. Top-up PAS fluid.
13. Start and run engine, operate steering lock to lock x2.
14. Top-up PAS fluid.
Power Assisted Steering (PAS) Rack -
Remove and Install
Removal
1. Disconnect the battery ground cable.
2. Remove the front undertray (refer to Workshop Manual Procedure 01.02.NB - Front Undertray).
3. Remove the front wheels and tyres (refer to Workshop Manual Procedure 04.04.ED - Wheel and Tyre - Pair).
4. Remove the front right side wheel-arch liner (refer to Workshop Manual Procedure 01.02.GB - Front Right
Side Wheel-Arch Liner).
5. Put a container in position under the oil tank to collect oil.
6. Remove the drain plug from the oil tank.
Figure 1
7. Let the oil drain into the container.
8. Install and tighten the drain plug into the oil tank (refer to Figure 1).
9. Remove the container.
10. Lower the vehicle.
11. Remove the radiator closing panel (refer to Workshop Manual Procedure 01.02.AA - Radiator Closing Panel).
Repair Operation Time (ROT)
Repair Operation Time (ROT)
Repair Operation Time (ROT)
ItemCode
Power Assisted Steering (PAS) Rack -
Remove and Install 11.02.AA
Page 653 of 947
Instrument Cluster (13.01)
Information, Gauge and Warning (13.00)13-1-2 Workshop Manual May 2007
Information, Gauge and Warning (13.00)
Instrument Cluster (13.01)
Description
The Driver Information module contains the necessary electronic control units and memories to control, process and
present all necessary vehicle information to the driver.
1. Information on vehicle performance is presented in visible form using the instruments and gauges. These
devices present such information as Vehicle Speed,
Engine Speed, Fuel Level and Coolant Temperature.
2. Information on vehicle status is presented by an array of warning lights.
• Red - indicate immediate danger warnings
• Amber - indicate conditions which are serious but not immediately dangerous
• Green and Blue - indicate normal actuation of items such as turn signals or fog lamps
The message centres and the shift position Sensor
display are used to present information on the distance
recorders (trip meters), current gear mode and current
gear engaged.
3. The right message centre is used to display any warning/ information message text. These text messages may be
reinforced in some cases by illumination of the
appropriate warning lamps.
The following table defines all information and warning
lamps and their significance:
) X H O
* D X J H 2 G R P H W H U 0 H V V D J H
& H Q W U H / H I W 6 K L I W
3 R V L W L R Q 6 H Q V R U 0 H V V D J H
& H Q W U H 5 L J K W 5 H Y
& R X Q W H U & R R O D Q W
7 H P S H U D W X U H * D X J H
Page 654 of 947
Instrument Cluster (13.01)
Information, Gauge and Warning (13.00)
May 2007 Workshop Manual 13-1-3
Information and Warning Lamps
Name / FunctionDescriptionSymbolInput SignalPower
On Check
General Warning
– Amber/Red Controlled internally by the DIM. It is used in conjunction with
several text messages to indicate information to the driver. Internal
SRS (Airbag) Controlled externally by the SRS module and indicates a fault in the SRS module. CAN Yes (5 Seconds)
High Engine
Coolant Temp. This tell tale is controlled internally by the DIM. Activated
when the engine coolant temperature signal from the CAN bus
reaches a pre defined value. (The
actual symbol is not lit, only
the red LED.) CAN
DSC Controlled externally by the ABS/DSC module. Indicates when the system is in operation or when it is turned off. The tell tale
is triggered by a CAN signal. CAN Yes (5 Seconds)
ABS Controlled externally by th e ABS/DSC module. Indicates a
fault in the ABS system. The tell tale is triggered by a CAN
signal. CAN Yes (5 Seconds)
Rear Fog Lights Controlled externally by the SRS module. Indicates that the
rear fog lights are turned on. The tell tale is triggered by a CAN
signal. CAN Yes (5 Seconds)
Seat Belts Controlled externally by the CEM. Indicates that the seat belts are not fastened properly. The tell tale is triggered by a CAN
signal. CAN Yes (5 Seconds)
Brake (General) Controlled externally by either the CEM or the ABS / DSC module. It indicates low brake fluid level, brake fault and park
brake. The tell tale is triggered by two low side inputs or a CAN
signal. Low side x 2
and
CAN Ye s ( 5 S e c o n d s )
Side Lights Controlled externally by th e CEM. Indicates that the side lights
are on. High side
Oil Pressure Controlled exte rnally by the PCM. Indicates low oil pressure.
The tell tale is triggered by a CAN signal. CAN Yes (5 Seconds)
Battery Charge Controlled externally by th e CEM. Indicates that the alternator
is no longer charging the battery properly. The tell tale is
triggered by a CAN signal. CAN Yes (5 Seconds)
Fuel Level Low Controlled internally by the DIM. Activated when the fuel level drops below a pre defined value. The fuel information is
provided from the CAN bus. The symbol is not lit, only the
amber LED. CAN
Turn Left/Right Controlled externally by th e CEM. The tell tale is triggered by a
CAN signal. CAN
High Beam Controlled externally by the CEM. Indicates that the high beam is switched on. The tell tale is triggered by a CAN signal. CAN
Check Engine Controlled externally by the PCM. Indicates a fault in the engine management system. The te ll tale is not connected to
the microprocessor. Low side
Tyre Pressure Controlled by the DIM. In dicates a low or rapid change in the
tyre pressure or a tyre pressure monitoring system fault. Low side Yes (5 Seconds)
Not Used
PATS Controlled externally by the PCM. Indicates key acceptance status. Low side
Page 666 of 947
Alternator and Regulator System (14.02)
Power Supply (14.00)
May 2007 Workshop Manual 14-2-1
Power Supply (14.00)
Alternator and Regulator System (14.02)
Description
The alternator installed to this vehicle is a Denso, SC1, 120
amp rating, with a 14.4 volt regulator.
The Alternator has an 'Altmon' signal that goes to and from
the PCM via a wire in the 3 way connector.
The ‘Altmon’ signal is monitored by the PCM which adjusts
ignition timing and fuelling if necessary to maintain idle
speed when the alternator is charging.
Specifications
Maintenance
Alternator-Renew
Removal
1. Battery isolation switch ‘OFF’.
2. Disconnect breather pipe qu ickfits (x2) from air cleaner
duct.
3. Remove throttle body du ct for access (clips x3).
4. Release tensioner and slip belt from idler.
5. Move belt off alternator pulley.
6. Reposition oil tank (to release alternator).
7. Remove breather pipe (quick fit).
8. Remove pipes (x2) fr om oil tank, tie aside.
9. Remove bolts (x4) securing tank to body, support tank and move aside to left side of engine bay. 10. Disconnect top hose from engine (clip x1) tie aside
(catch coolant).
11. Raise vehicle on ramp.
12. Remove undertray (see Workshop Manual procedure 01.02.NB Undertray - Front - Renew).
13. Remove bolts (x3) securing oil thermostat to body (allows oil tank more sideways movement).
14. Remove road wheel/s.
15. Remove oil filter and renew (see Workshop Manual procedure 03.02.AB Filter - Oil Canister Renew).
16. Reposition heatsheild to gain access to top bolt.
17. Unclip harness from bracket for access to top bolt and move aside.
18. Remove top securing nut and bolt.
19. Remove nut from bottom fixing and withdraw bolt (will foul on front subframe).
20. Lever alternator forward to release clamping of sliding bushes.
21. Using suitable grips remove bottom/ front sliding bush together with bolt.
22. Position alternator for access, disconnect battery (nut x1) lead and multiplug.
23. Lower ramp.
24. Remove alternator via front of engine (oil tank).
Installation
1. Install alternator.
2. Raise ramp.
3. Connect battery lead and multiplug to alternator.
4. Position alternator to bracket, install top fixing nut and bolt (do not tighten).
5. Install bottom bolt with sliding bush into bracket (through alternator).
6. Install nut to bottom bolt and tighten (torque).
7. Tighten top nut and bolt (torque)
8. Install oil filter and re new (see Workshop Manual
procedure 03.02.AB Filter - Oil Canister Renew).
9. Clip harness to bracket.
10. Reposition heatsheild to original position.
11. Install bolts (x3) securing oil thermostat to body (torque).
12. Install undertray (see Workshop Manual procedure 01.02.NB Undertray - Front - Renew).
13. Install road wheel/s
14. Lower vehicle on ramp.
15. Reposition oil tank.
16. Connect top hose to engine (clip x1).
17. Position tank to body and fit bolts (x4) (torque).
18. Install oil pipes to tank.
19. Connect breather hose.
20. Fit belt to alternator pulley.
Torque Figures
DescriptionNmlb/ft
Alternator mounts 43-52 32-38.5
Repair Operation Time (ROT)
Page 667 of 947
Alternator and Regulator System (14.02)
Power Supply (14.00)14-2-2 Workshop Manual May 2007
21. Release tensioner and slip belt on idler.
22. Install throttle body duct.
23. Connect breather pipe quickf its (x2) to air cleaner duct.
24. Battery isolation switch ‘ON’.
25. Top up coolant.
Page 714 of 947
Wiring and Circuit Protection (18.01)
Electric Distribution/Electronic Control (18.00)
May 2007 Workshop Manual 18-1-25
45. Disconnect multiplugs (x4) knock sensors (see Fig. 13).
46. Disconnect multiplug (x 1) secondary air pump.
47. Disconnect multiplug (x1) engine coolant temperature.
48. Disconnect earth lead.
49. Disconnect multiplugs (x2) suppressors
50. Remove bolts (x2) rear engine harness support bracket.
51. Cut cable ties (x7) harn ess to rear support bracket.
52. Release harness multiplugs (x4) from rear harness support bracket
53. Release and remove harness from remaining clip positions (x8).
Installation
1. Secure multiplugs (x4) and the harness with cable ties to rear support bracket.
2. Secure harness (x8) and install rear harness support bracket.
3. Connect multiplugs (x2) suppressors
4. Connect earth lead.
5. Connect multiplug (x1) engine coolant temperature.
6. Connect multiplug (x1) secondary air pump.
7. Connect multiplugs (x4) knock sensors.
8. Connect multiplug (x1) air control valve solenoid.
9. Connect multiplugs (x2) CMP sensors.
10. Position and secure engine harness in clips (x25)
11. Install inlet manifold
12. Install heater hose brackets (x2)
13. Secure engine harness to LH and RH heater hose brackets.
14. secure heater hose to he ater hose brackets (x2).
15. Connect breather hose to manifold.
16. Secure servo hose.
17. Install LH and RH support brackets
18. Connect multiplug (x1) condenser.
19. Connect multiplug (x1) throttle body.
20. Connect multiplug (x1) in let air temperature sensor.
21. Disconnect multiplug (8) to injectors. 22. Secure harness clip to ridge of cam covers (x2).
23. Connect multiplugs (x2) VVT solenoid.
24. Connect multiplugs (x8) to ignition coils.
25. Secure HEGO engine harn
ess connections (x4) to
mounting bracket.
26. Connect multiplug (x1) crankshaft sensor.
27. Connect multiplug (x1) starter motor.
28. Connect multiplugs (x2) oil pressure and temperature switches.
29. Connect multiplug (x1) alternator.
30. Secure vacuum pipe to heater hose bracket clips (x2).
31. install bolt (x1) purge valv e pipe to RH support bracket.
32. Connect multiplug (x1) fuel rail pressure sensor.
33. Install coil covers.
34. Install LH and RH exhaust ma nifolds, install and torque
tighten nuts (x16).
35. Install slings to engine lifting brackets, connect and raise hoist.
36. Lower engine onto subframe, align hydramounts, install and torque tighten nuts (x2).
37. Disconnect hoist from slings, move hoist aside.
38. Remove slings from engine.
39. Remove lifting brackets from engine, (303-749 and (303-536).
40. Clean EGR module, pipe union and mating faces.
41. Install new gasket, install EGR module, install and torque tighten bolts (x2)
42. Install EGR pipe, torque tighten union.
43. Connect multiplug and vacuum pipe to EGR module.
44. Install engine (see Wo rkshop Manual procedure
03.00.AC Engine Assembly - Remove for access and
refit).
Facia Harness-Renew
Removal
1. Remove IP assembly (see Workshop Manual procedure
01.12.AB Instrument Panel - Facia Assembly - Remove
for access and refit).
2. Disconnect multiplugs (x 6) from heater assembly.
3. Remove nuts (x2) and bolt (x 1) heater assembly to facia.
4. Remove instrument panel bezel assembly (see Workshop Manual procedur e 01.12.AV Bezel Assembly
- Instrument Panel - Renew).
Fig. 13
$
Warning
Always connect the battery earth (- ve) terminal last.
Repair Operation Time (ROT)
Warning
To prevent damage to electrical components, always disconnect the vehicle battery when working on the
vehicle's electrical system. The earth lead (- ve) must be disconnected first an d reconnected last.
Page 742 of 947
Fluids/Capacities
Appendix & Glossary
May 2007 Workshop Manual 20-1-3
Fluids/Capacities
Terms
Frequently used alternative names or spellings for vehicle
components mentioned in this Workshop Manual.
Capacities
Europe UK USA
Engine sump (incl. filter) 9 .5 litres 16.7 pints 10.0 Qts
Engine sump (excl. filter) 8 .5 litres 15.0 pints 9.0 Qts
Engine cooling system 12 litres 21 pints 14.4 Qts
Screen washer reservoir 2.0 litres 3.5 pints 2.2 Qts
Gearbox & Cooler 4.7 litres 7.9 pints 5.6 Qts
Final drive 2.0 litres 3.5 pints 2.2 Qts
Fuel tank 80.0 litres 17.6 galls 88.0 Qts
Recommended Fluids
Engine oil (Initial fill) Castrol Edge Sport 10w60
Do not mix Engine oil with any mineral oils.
Engine coolant 50% water, 50% OAT Coolant (Arteco Havoline XLC only)
Do not mix OAT coolant with any glycol based anti-freeze.
Gearbox oil Shell Transaxle Oil 75w90
Final drive oil Mobil 1 80w140
Brake fluid Castrol Super Response DOT4
Power steering fluid Esso Power steering Fluid
A/C Refrigerant R134A (HFC134A)
A/C Compressor oil ND8
UK EnglishUS English
Bonnet Hood
Boot Trunk
Brake Disc Rotor
Handbrake Parking Brake
Petrol Gasoline
Tyre Tire
Wing Fender
Windscreen Windshield
Sill Rocker Panel