Timing ASTON MARTIN V8 VANTAGE 2010 Manual PDF
[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 406 of 947
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
Page 407 of 947
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)
A0311247
Page 408 of 947
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
Page 409 of 947
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
A0311246A
Page 410 of 947
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.
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 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 749 of 947
Special Tools - Pictorial Index
Appendix & Glossary20-1-10 Workshop Manual May 2007
303-F715-07 (Trolley Adaptor)
308-641 (Gear Shift Locking Tool)
308-642 (Gear Shift Cable Release Tool)
Part No./Description
310-155 (Fuel Tank Drain Adaptor)
303-1215 (Camshaft Aligner)
303-1216 Timing Chain Tensioner
Part No./Description
Page 871 of 947
AML EOBD System Operation Summary
Rory O’Curry Aston Martin Lagonda CONFIDENTIAL 1 May 2009
[email protected] AML EOBD Monitors 07 ROC.doc Page 25 of 43
VCT Monitor
Variable Cam Timing System Monitor
VCT Hardware
Variable Cam Timing (VCT) enables rotation of the camshaft(s) relative to the crankshaft (phase-shifting)
as a function of engine operating conditions. Intake Only (phase-shifting only the intake cam) is used in
the AML application.
VCT is used primarily to increase internal residua l dilution at part throttle to reduce NOx, and to
improve fuel economy. With Intake Only VCT, the in take camshaft is advanced at part throttle and WOT
(at low to mid-range engine speeds) to open the in take valve earlier for increased residual dilution and
close the intake valve earlier in the compression stroke for increased power. When the engine is cold,
opening the intake valve earlier warms the charge which improves fuel vaporization for less HC
emissions; when the engine is warm, the residua l burned gasses limit peak combustion temperature to
reduce NOx formation.
The VCT system hardware consists of a contro l solenoid and a pulse ring on the camshaft. The PCM
calculates relative cam position using the CMP input to process variable reluctance sensor pulses coming
from the pulse ring mounted on the camshaft. Each pul se wheel has N + 1 teeth where N = the number of
cylinders per bank. The N equally spaced teeth are used for cam phasing; the remaining tooth is used to
determine cylinder # 1 position. Relative cam position is calculated by measuring the time between the
rising edge of profile ignition pickup (PIP ) and the falling edges of the VCT pulses.
VCT Diagnostic
The PCM continually calculates a cam position error value based on the difference between the desired
and actual position and uses this information to cal culate a commanded duty cycle for the VCT solenoid
valve. When energized, engine oil is allowed to flow to the VCT unit thereby advancing and retarding cam
timing. The VCT logic calculates the instantaneous va riance in actual cam position (the squared difference
between actual cam position and commanded cam position), then calculates the long term variance using a
rolling average filter (Exponentially Weighted Moving Average).
If the VCT system is stuck or operates with an consta nt error relative to the target position, the monitor
will detect a variance which will quickly accumulate. There are three variance indices that monitor cam
variance in the retard direction, the advance directi on, and for V engines, the difference between banks. If
any variance index is greater than the malfunction threshold, a VCT target error malfunction will be
indicated (P0011, P0012 Bank 1, P0021, P0022 Bank 2).
The VCT solenoid output driver in the PCM is check ed electrically for open circuit and shorts (P0010
Bank 1, P0020 Bank 2).
VCT Monitor Operation:
Page 873 of 947
AML EOBD System Operation Summary
Rory O’Curry Aston Martin Lagonda CONFIDENTIAL 1 May 2009
[email protected] AML EOBD Monitors 07 ROC.doc Page 27 of 43
Comprehensive Component Monitor - Engine
General Inputs
Analog inputs such as Ambient Air Temperature (P0072, P0073), Intake Air Temperature (P0112, P0113),
Engine Coolant Temperature (P0117, P0118), Cylinder Head Temperature (P1289, P1290), Mass Air Flow
(P0102, P0103) and Manifold Absolute Pressure (P0107, P0108) are checked for opens, shorts, or out-of-
range values by monitoring the analog -to-digital (A/D) input voltage.
Analog Sensor Check Operation:
DTCs P0072, P0073, P0112, P0113, P0117, P0118, P0102, P0103, P0107, P0108,
P1289, P1290
Monitor execution continuous
Monitor Sequence none
Monitoring Duration 5 seconds to register a malfunction
Typical analog sensor check malfunction thresholds:
Voltage < 0.20 volts or voltage > 4.80 volts
On Vehicles fitted with Cylinder Head Temperature (CHT ) Sensors, 'Fail Safe Cooling' can be applied if
the cylinder head temperature is too high. The P1299 DTC will be set under these conditions.
Loss of Keep Alive Memory (KAM) power (a separate wire feeding the PCM) results in a P1633 DTC and
immediate MIL illumination.
Loss or corruption of the Vehicle Identification (VID) Block in the PCM results in a P1639 DTC and
immediate MIL illumination.
Ignition
Electronic Ignition systems (Electronic Distributorless Ignition System - EDIS or Coil on Plug - COP)
systems are used on all applications.
The EDIS system, located in the PCM, processes the 36 (or 40) tooth crankshaft position signal to
generate a low data rate PIP signal to control a 4 or 6 terminal 'double-ended' coil pack. The 'double ended'
coils fire a pair of spark plugs simultaneously - one is on its compression stroke, the other on its exhaust
stroke. The COP system also uses the EDIS system in the same way as described above, however each
sparkplug has it’s own coil which is fired only once on the compression stroke.
The ignition system is checked by monitoring three ignition signals during normal vehicle operation:
Profile Ignition Pickup (CKP, commonly known as PIP), the timing reference signal derived from the crankshaft 36-tooth wheel and processed by the EDIS system. PIP is a 50% duty cycle, square
wave signal that has a rising edge at 10 ° BTDC.
Camshaft IDentification (CMP, commonly known at CID), a signal derived from the camshaft to identify the #1 cylinder