lock ASTON MARTIN V8 VANTAGE 2010 Manual PDF

Valve Train (03.09)
Engine (03.00)3-9-20 Workshop Manual Issue 5, January 2010
3. Remove the two bolts that attach the secondary timing chain tensioner to the cylinder head (refer to Figure 2).
Figure 2
4. Release and remove the camshaft sprockets complete with the timing chain and te nsioner from the camshafts
(refer to Figure 3).
Figure 3
5. Remove the secondary timing chain and tensioner from the sprockets (refer to Figure 4).
Figure 4
Install
1. Clean the camshaft sprockets and tensioner.
2. Install the secondary timing chain and tensioner to the camshaft sprockets. 3. Install the secondary timing chain assembly onto the
camshafts.
4. Install the spacer onto the M12 exhaust Torx bolt.
5. Install the exhaust M12 Torx bolt to attach the exhaust camshaft sprocket. Do not tighten at this step.
6. Install the inlet M12 Torx bolt to attach the inlet camshaft sprocket. Do not tighten at this step.
7. Install and torque tighten the two secondary tensioner bolts.
8. Install the left-side pr imary timing chain guide.
9. Install and torque the bolt that attaches the chain guide.
10. Make sure that the timing ch ain slack is on the tensioner
side of the timing chain.
11. Install the primary timing chain.
12. Install the tensioner blade for the primary timing chain.
13. Install and torque the bolt that attaches the tensioner blade.
14. Install the primary timing chain tensioner assembly.
15. Install and torque the two bolts that attach the primary chain tensioner.
16. Release the tension on the timing chain tensioner piston. Remove the retaining special tool.
17. Install the timing chain tensioning tool (303-532) on the exhaust camshaft sprocket.
18. Apply a force to the special tool (303-532) in a counterclockwise direction and torque the sprocket
Torx bolts. Remove the special tool.
19. Install the the left and right primary timing chain (refer to
Workshop Manual procedure 03.09.BM/03.09.BN/
03.09.CM/03.09.CN Timing Chain - Primary - LH/RH -
Renew With Engine Removed).
RH/LH Intake Camshaft Renew With
Engine Removed
Remove
1. Remove the left and right secondary timing chain tensioner (refer to Work shop Manual procedure
03.09.BS/03.09.BR Tensioner Assembly - Secondary -
RH/LH - Renew With Engine Removed).
2. Remove the three bolts that attach the tool (303-530) to
the cylinder head.
A0309256
A0309254
A0309255
Repair Operation Time (ROT)
ItemCode
Intake Camshaft-Renew LH03.09.BT
Intake Camshaft-Renew RH03.09.BV
WAR NI NG
DO NOT GET USED ENGINE OIL ON YOUR SKIN. USED ENGINE OIL CAN BE HARMFUL.

Valve Train (03.09)
Engine (03.00)
Issue 5, January 2010 Workshop Manual 3-9-25
13. Install and torque the M6 attachment bolt for the tensioner blade.
14. Install the tensioner assembly for the primary timing chain.
15. Install and torque the two M6 bolts that attach the tensioner assembly.
16. Release the tension on the piston of the timing chain tensioner.
17. Remove the retaining special tool.
18. Install the timing chain tensioning tool (303-532) into the exhaust camshaft sprocket.
19. Apply a force to the tool (303-532) in a counterclockwise direction and torque the M12
sprocket Torx bolts.
20. Remove the special tool.
21. Install the left and right primary timing chain (refer to Workshop Manual procedure 03.09.BM/03.09.BN
Timing Chain - Primary - LH /RH - Renew With Engine
Removed).
RH/LH Intake Camshaft Sprocket and
Housing Assembly-Renew
Remove
1. Remove the left and right pr imary timing chain (refer to
Workshop Manual procedure 03.09.AN/03.09.AM/
03.09.CN/03.09.CM Chain - Timing Primary - RH/LH -
Renew). 2. Remove the two M12 Torx bolts that attach the inlet
and exhaust camshaft sprockets to camshafts (refer to
Figure 1).
Figure 1
3. Collect the spacer from the bolt on the exhaust camshaft.
4. Remove the two M6 bolts that attach the secondary timing chain tensioner to the cylinder head (refer to
Figure 2).
Figure 2
Caution
Apply an opposite force to the sprockets and chain while
you tighten the sprocket bolts
Repair Operation Time (ROT)
A0309252
A0309253

Valve Train (03.09)
Engine (03.00)3-9-26 Workshop Manual Issue 5, January 2010
5. Release and remove the two camshaft sprockets complete with the timing chain and tensioner from the
camshafts (refer to Figure 3).
Figure 3
6. Remove the intake sprocket housing assembly from the secondary timing chain (refer to Figure 4).
Figure 4
Install
1. Clean the two camshaft sprockets and the tensioner.
2. Install intake sprocket housing assembly and exhaust sprocket into secondary timing chain.
3. Install secondary timing ch ain tensioner onto timing
chain.
4. Install secondary timing chain assembly onto camshafts.
5. Install the spacer onto the M12 exhaust Torx bolt.
6. Install the exhaust M12 Torx bolt to attach the exhaust camshaft sprocket. Do not tighten at this step.
7. Install the inlet M12 Torx bolt to attach the inlet camshaft sprocket. Do not tighten at this step.
8. Install and torque tighten secondary tensioner bolts (x2).
9. Install RH primary timing chain guide, install and torque tighten bolt.
10. Make sure that the timing chain slack is on the tensioner side of the timing chain.
11. Install primary timing chain.
12. Install primary timing chain tensioner blade, install and
torque tighten bolt. 13. Install primary timing chai
n tensioner assembly, install
and torque tighten bolts (x2).
14. Release tension on the ti ming chain tensioner piston,
remove retaining special tool.
15. Install timing chain tens ioning tool (303-532) into
exhaust camshaft sprocket.
16. Apply a force to the tool (303-532) in an anti-clockwise direction and torque tighte n sprocket Torx bolts.
Remove special tool.
17. Install RH/LH primary timing chain (refer to Workshop
Manual procedure 03.09.AN/03.09.AM/03.09.CN/
03.09.CM Chain - Timing Primary - RH/LH - Renew).
Left Side Primary Chain - Remove and
Install
)
Remove
1. Remove the right side primar y timing chain. (refer to
procedure 03.09.CN - Right Side Primary Timing Chain)
2. Remove the two bolts that attach the left side bush carrier for the Variable Camshaft Timing (VCT) to the
engine.
Figure 1
A0309254
A0309255
Caution
Apply an opposite force to the sprockets and chain while you tighten the sprocket bolts
Repair Operation Time (ROT)
ItemCode
Left Side Primary Chain - Remove and Install 03.09.CM

Valve Train (03.09)
Engine (03.00)
Issue 5, January 2010 Workshop Manual 3-9-27
3. Remove the nut that attaches the left side bush carrier for the VCT to the engine.
Figure 2
4. Remove the left side bush carrier for the VCT.
Figure 3
5. Loosen the two bolts that attach the timing chain tensioner to the engine.
Figure 4
6. Release the ratchet lock on the timing chain tensioner and push the piston into the tensioner housing.
Figure 5
7. Install an applicable pin into the timing chain tensioner.
Figure 6
8. Remove the two bolts that attach the timing chain tensioner to the engine.
Figure 7
9. Remove the timing chain tensioner.

Valve Train (03.09)
Engine (03.00)
Issue 5, January 2010 Workshop Manual 3-9-29
2. Install the timing chain (refer to Figure 12).
3. Install the timing chain guide (refer to Figure 11).
4. Install the bolt that attach es the timing chain guide to
the engine. Torque the bolt to 11 Nm.
5. Install the tensioner arm.
6. Install the bolt that attaches the tensioner arm to the engine. Torque the bolt to 11 Nm.
7. Install the timing chain tensioner.
8. Install and torque the two bolts that attach the timing chain tensioner to the engine to 11 Nm.
9. Install the special tool onto the exhaust camshaft sprocket. 10. Note: Use the special tool to hold the timing chain in
the correct place during the next two steps of the
procedure.
11. Use the special tool to turn the exhaust sprocket counterclockwise until there is tension in the chain.
12. Note: Make sure that the tensioner is fully operated but do not use too much force.
13. Release the pin from the timing chain tensioner and let the tension piston gradually tension the timing chain.
14. Note: Make sure that you to rque the bolt that attaches
the sprocket to the exhaust camshaft first in the step that
follows.
15. Torque the two Torx bolts that attach the camshaft sprockets to the camshafts to 20 Nm.
16. Note: Make sure that you to rque the bolt that attaches
the sprocket to the exhaust camshaft first in the step that
follows.
17. Tighten the two Torx bolts that attach the camshaft sprockets to the camshafts 90 degrees more.
18. Remove the special tool from the exhaust camshaft sprocket.
19. Install the left side bush carrier for the VCT.
20. Install the two bolts that attach the left side bush carrier for the VCT to the engine. Torque the two bolts to 21
Nm.
21. Install the nut that attaches the left side bush carrier for the VCT to the engine. Torque the nut to 11 Nm.
22. Install the right side primar y timing chain. (refer to
procedure 03.09.CN - Right Side Primary Timing
Chain).
RH/LH Intake Camshaft Sprocket and
Housing Assembly-Renew (with Engine
Removed
)
Remove
1. Remove the right and left primary timing chains (refer to Workshop Manual procedure 03.09.BN/03.09.BM
Timing Chain - Primary - RH/LH - Renew With Engine
Removed).
Repair Operation Time (ROT)

Valve Train (03.09)
Engine (03.00)3-9-30 Workshop Manual Issue 5, January 2010
2. Collect the spacer from the bolt on the exhaust camshaft.
Figure 1
3. Remove the two M6 bolts that attach the secondary timing chain tensioner to the cylinder head (refer to
Figure 2).
Figure 2
4. Release and remove camshaft sprockets complete with timing chain and tensioner from camshafts (refer to
Figure 3).
Figure 3
5. Remove intake sprocket housing assembly from secondary timing chain (refer to Figure 4).
Figure 4
Install
1. Clean the two camshaft sprockets and the tensioner.
2. Install the intake sprocket housing assembly and the exhaust sprocket into the secondary timing chain.
3. Install the secondary timing chain tensioner onto the timing chain.
4. Install the secondary timing chain assembly onto the camshafts.
5. Install the spacer onto the M12 exhaust Torx bolt.
6. Install the exhaust M12 Torx bolt to attach the exhaust camshaft sprocket. Do not tighten at this step.
7. Install the inlet M12 Torx bolt to attach the inlet camshaft sprocket. Do not tighten at this step.
8. Install and torque the two M6 bolts that attach the secondary tensioner.
9. Install the guide for the right primary timing chain.
10. Install and torque the M6 bolt that attaches the guide.
11. Make sure that the timing ch ain slack is on the tensioner
side of the timing chain.
12. Install the primary timing chain.
13. Install the tensioner blade for the primary timing chain.
14. Install and torque the M6 bolt that attaches the tensioner blade.
15. Install the primary timing chain tensioner assembly.
16. Install and torque the two M6 bolts that attach the tensioner assembly.
17. Release the tension from the timing chain tensioner piston and remove the retaining special tool.
18. Install the timing chain te nsioning tool (303-532) into
the exhaust camshaft sprocket.
19. Apply a force to the tool (303-532) in a counterclockwise direction and torque the two M12
sprocket Torx bolts.
20. Remove the special tool.
21. Install the left and right primary timing chain (refer to Workshop Manual procedure 03.09.BN/03.09.BM
A0309252
A0309253
A0309254
Caution
Apply an opposite force to the sprockets and chain while you tighten the sprocket bolts.
A0309255

Engine Sealing (03.10)
Engine (03.00)3-10-2 Workshop Manual Issue 5, Janauary 2010
21. Remove the M10 bolt that attaches the auxiliary drive belt tensioner and remove tensioner (Refer to Figure 3).
Figure 3
22. Remove the two bolts that attach the inspection cover to lower crankcase and remove the cover.
23. Install the tool (303-1185) to hold the flywheel. Install and tighten the two bolts.
24. Remove and discard the M16 screw that attaches the crankshaft pulley.
25. Install the thrust-button of tool (303 -1186) into crankshaft.
26. Put the tool into the pulley.
27. Attach the tool with the two bolts.
28. Turn the centre bolt clockwise to withdraw the pulley from the crankshaft.
29. Collect the crankshaft pulley, locking ring and the thrust button for the special tool.
30. Remove the special tool from the pulley.
31. Remove and discard the O-ring seal from the pulley.
32. Remove the bolt that attaches the alternator idler pulley and remove the pulley.
33. Remove the bolt that attaches the idler pulley for the air- conditioning compressor and remove the pulley.
34. Put an applicable container under the oil filter to collect drained oil.
35. Remove the oil filter.
36. Release the oil separator drain tube from the timing cover.
37. Release the clip for the oil separator drain tube from the bracket.
38. Release the cover for the battery cable from the alternator. 39. Remove the nut that attaches the battery cable to the
alternator and remove the cable. (Refer to Figure 4).
Figure 4
40. Disconnect the electrical connector from the alternator.
41. Remove the M8 bolt that attaches the top of the alternator.
42. Remove the M10 bolt and the nut that attaches the bottom of the alternator and remove the alternator.
43. Remove the three Torx bolts that attach the alternator mounting bracket to the cylinder block.
44. Remove the bracket (Refer to Figure 5).
Figure 5
45. Remove the three M8 bolts that attach the PAS pump to the mounting bracket and move the pump away.
WAR NI NG
DO NOT GET USED ENGINE OIL ON YOUR SKIN.
USED ENGINE OIL CAN BE HARMFUL.
A030553A030582
A0310242

Engine Sealing (03.10)
Engine (03.00)
Issue 5, Janauary 2010 Workshop Manual 3-10-3
46. Remove the four M8 Torx bolts that attach the PAS pump mounting bracket to the cylinder block and
remove the bracket (refer to Figure 6).
Figure 6
47. Remove the 27 M6 bolts that attach the timing cover to the engine.
48. Collect the bracket for the oil separator drain tube.
49. Remove the timing cover.
50. Remove the outer and inner rubber seals from timing cover (Refer to Figure 7).
Figure 7
51. Remove the front crankshaft oil seal from the timing
cover.
Install
1. Examine the condition of the seal in the John Guest cartridge connector for the oil return pipe. If there are
signs that the connector has leaked, install a new John
Guest cartridge kit (Refer to ’John Guest Cartridge in the
Engine Timing Cover - Repair’, page 3-10-14).
2. Clean the timing cover and the mating face on the engine. 3. Install the inner and outer seals to the timing cover.
4. Apply 3mm x 12mm beads of sealant to the eight joints
on the engine.
5. Install the timing cover. Put the oil separator drain tube bracket in position and install the 27 M6 bolts..
6. Torque the 27 bolts in the sequence shown in Figure 8.
Figure 8
7. Use tool (303-750) to install the front crankshaft oil seal.
8. Remove the special tool and the seal protector.
9. Use an M16 x 2 plug tap to clean the thread in the crankshaft.
10. Clean the crankshaft pulley and mating face on the crankshaft.
11. Lubricate and install a new O-ring seal in the crankshaft pulley.
12. Examine the crankshaft pulley and the taper collet for damage. Replace all damaged parts.
13. Install the crankshaft pulley, taper collet and a new pulley bolt.
14. Torque tighten the crankshaft pulley bolt.
15. Remove the special tool (303-1185) from the crankcase.
16. Install the inspection cover to the lower crankcase, install and tighten the two attachment bolts.
17. Install the PAS pump mounting bracket. install and torque tighten the four M8 Torx bolts.
18. Install the PAS pump. Install and torque the three M8 bolts.
19. Install the alternator mounting bracket. Install and torque tighten the three M8 Torx bolts.
WA R N I N G
DO NOT GET USED ENGINE OIL ON YOUR SKIN.
USED ENGINE OIL CAN BE HARMFUL.
Caution
Make sure the cranks haft front oil seal mating faces are
clean and dry.
A0310243
A0310245
Caution
Do not remove the crankshaft front oil seal protector
until the oil seal is correctly installed.
Caution
Clean the thread in the cran kshaft before you install a
new crankshaft pulley bolt. If you do not you can not apply the correct torque to the bolt.

Engine Sealing (03.10)
Engine (03.00)3-10-6 Workshop Manual Issue 5, Janauary 2010
Right Side Cam Cover Gasket - Renew
1. Remove the right cam cover (Refer to ’Right Side Cam Cover - Remove and Install’, page 3-10-9).
2. Remove and discard the cam cover gasket.
Installation
1. Clean the mating faces of the cam cover and the cylinder head.
2. Put the new cam cover gasket in position.
3. Install the right cam cover (Refer to ’Right Side Cam
Cover - Remove and Install’, page 3-10-9).
Cylinder Head Gasket - Renew (Engine
Set)
Removal
1. Remove the SAI pump and bracket assembly (refer to procedure 03.08.DB Pump and Bracket Assembly -
Secondary Air Injection - Renew).
2. Disconnect the electrical connector from each of the two left and two right knock sensors.
3. Disconnect the electrical connector from the left and right camshaft timing sensors.
4. Remove the right exhaust manifold (refer to procedure 09.00.CC Gasket - Exhaust Manifold - RH - Renew).
5. Remove the left front wheel arch liner (refer to procedure 01.02.FB Wheel Arch Liner - Front - LH -
Renew).
6. Remove the eight nuts that attach the left exhaust manifold to cylinder head.
7. Remove the left exhaust ma nifold. Remove and discard
the gasket.
8. Remove the left intake camshaft (refer to Workshop Manual procedure 03.09.AV Camshaft - Intake - LH -
Renew). 9. Remove the 10 left exhaust camshaft bearing cap
attachment bolts evenly and in steps (refer to Figure 1).
Figure 1
10. Record the positions and the markings of the bearing caps for the left exhaust camshaft .
11. Remove the bearing caps for the left exhaust camshaft.
Figure 2
12. Remove the two bolts that attach the front end of the left cylinder head to the cylinder block.
Repair Operation Time (ROT)
Repair Operation Time (ROT)
A0309270
A0309272

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
A0310319
A0309252
A0309253
A0309254
A0309271