maintenance ASTON MARTIN V8 VANTAGE 2010 Manual PDF

May 2007 Workshop Manual 8-1-1
Clutch (08.00)
Contents
Clutch Assembly (08.01)........................................ 8-1-2Description ............................................................. 1-2
Specifications.......................................................... 1-2
Maintenance ........................................................... 1-2 Clutch and Flywheel Assembly-Renew ................... 1-2
Slave Clutch Cylinder-Renew ................................. 1-3
Clutch Bleed Hose Assembly-Renew ...................... 1-4
Clutch Hydraulic System-Bleed-Sportshift Only ...... 1-4
Clutch Hydraulic System-Bleed .............................. 1-5
Master Cylinder to Slave Cylinder Tube
Assembly-Renew-Sportshift Only............................ 1-5

Clutch Assembly (08.01)
8-1-2 Workshop Manual May 2007
Clutch (08.00)
Clutch Assembly (08.01)
Description
The clutch assembly consists of a balanced flywheel, a clutch
driven plate and a clutch cover.
The clutch is a single plate, diaphragm spring type assembly.
A concentric clutch slave cylinder is mounted around the
first motion shaft in the torque tube bell housing.
The clutch master cylinder is mounted on the engine
bulkhead and is operated directly by the clutch pedal.
A hydraulic connection from the master cylinder feeds
pressurised fluid to the slave cylinder. The slave cylinder has
an extension tube and bleed nipple extending from the left
side of the bell housing for bleeding the system after any
major work.
Specifications
Maintenance
Clutch and Flywheel Assembly-Renew
08.00.AA
Removal
1. Disconnect vehicle battery.
2. Raise vehicle on ramp.
3. Remove torque tube assembly (see Workshop Manual procedure 05.01.CA Torque Tube Remove for Access
and Refit).
4. Remove bolts (x2) from inspection cover to lower crankcase and remove cover. 5. Install special tool SKAM14546 OT to restrain flywheel
and install and tighten bolts (x2) (see Fig. 1).
6. Remove bolts (x6) from clutch cover to flywheel (see Fig.
2).
7. Release clutch cover from dowels, remove cover and collect drive plate.
Clutch Fluid
Castrol/Girling Universal Brake and Clutch fluid.
Clutch Assembly
Clutch and flywheel are separately balanced.
Clutch Plate
Single 267mm driven plate.
Torque Figures
DescriptionNmlb/ft
Flywheel Bolts
Tighten the bolts in sequence. Loosen
the bolts and then torque, in even
stages, in the same sequence. 100 -
120
74-
88.5
Clutch Bolts
Tighten x6 equally-spaced bolts, in-
turn, to pull-down the clutch evenly.
Then torque all bolts in sequence. 65-75 48-55
Starter Motor Bolts 42.5-
57.531.5-
42.5
Repair Operation Time (ROT)
Fig. 1
Fig. 2
Warning
The clutch assembly is heavy. Ensure the clutch
assembly is supported befo re removing final bolts.



Issue 5, January 2010 Workshop Manual 9-1-1
Exhaust (09.00)
Contents
Exhaust Overview .................................................. 9-1-2
Silencer Assembly (09.01) ..................................... 9-1-3Variable Flow Silencer Assembly ............................ 1-3
Maintenance ........................................................... 1-3 LH Catalyst & Pipe Assembly-Renew ...................... 1-3
RH Catalyst & Pipe Assembly-Renew ..................... 1-3
LH Exhaust Manifold-Renew-Roadster Only ........... 1-4
Heated Exhaust Gas Oxygen (HEGO) Sensor
- Remove and Install .............................................. 1-4
Silencer and Bypass Valve Assembly-Remove for
Access/Refit-Coupe Only........................................ 1-5
Silencer and Bypass Valve Assembly-Remove for
Access/Refit-Roadster Only .................................... 1-5
Silencer and Bypass Valve Assembly-Renew ........... 1-6
Exhaust Rear Silencer Mounting Rubber-Renew ..... 1-7
Exhaust System-Renew........................................... 1-7
Exhaust System (Excludi ng Manifold/Downpipes)
-Renew .................................................................. 1-8
Pipes and Supports (09.03) ................................... 9-2-1 Specifications.......................................................... 2-1
Maintenance ........................................................... 2-1RH/LH Catalyst and Pipe Assembly-Renew............. 2-1
Exhaust Centre Pipe-Renew ................................... 2-1
RH Exhaust Manifold-Renew.................................. 2-2
LH Exhaust Manifold-Renew .................................. 2-2
RH Exhaust Manifold Gasket-Renew ...................... 2-3
LH Exhaust Manifold Gasket-Renew....................... 2-3
Exhaust Gas Temperature Sensor-Renew................ 2-4
Exhaust Gas Heated Temperature Sensor-Renew ... 2-4
RH/LH Rear Exhaust Pipe Assembly-Renew............ 2-5

Silencer Assembly (09.01)
Exhaust (09.00)
Issue 5, January 2010 Workshop Manual 9-1-3
Exhaust (09.00)
Silencer Assembly (09.01)
Variable Flow Silencer Assembly
The rear silencer assembly has a variable fl ow path controlled by two bypass valves.
The system is intended to enhance top end performance in mo tor sport applications and will not operate in most normal
driving conditions.
By directing exhaust gasses through a modified path at high vehicle speeds, exhaust back pressure is reduced and top end
performance is enhanced.
As engine speed increase from idle, the bypass valve is open until the engine speed is 1500 rpm.
From 1500 rpm to 3000 rpm, the valve is closed
Above 3000 rpm the bypass valves state is load dependent (fully open at higher loads).
Maintenance
LH Catalyst & Pipe Assembly-Renew
Removal
1. Raise vehicle on ramp.
2. Remove rear exhaust silencer (refer to Workshop Manual procedure 09.00.KA Muffler & Bypass Valve
Assembly - Remove for Access & Refit).
3. Disconnect multiplugs (x2), HEGO sensors.
4. Release sensor lead from clip on heatshield.
5. Secure sufficient lengths of string to HEGO sensor multiplugs for assembly purposes.
6. Loosen LH and RH clamp nuts , catalysts to centre pipe.
7. Remove nuts (x3), catalyst to exhaust manifold.
8. With assistance, manoeuvre exhaust centre pipe assembly rearwards to release from catalysts.
9. With assistance, release and support weight of LH catalyst from exhaust manifold.
10. Manoeuvre HEGO sensor le ads and remove cable tie.
Release HEGO sensor leads from behind heat shield.
Secure cable tie. Remove string from HEGO multiplugs.
11. Remove catalyst assembly.
12. Remove and discard gasket. 13. Remove HEGO sensor
s (x2) from catalyst.
Installation
1. Clean catalyst, mating joint faces and HEGO sensors..
2. Install and tighten HEGO sensors (x2) to catalyst.
3. Apply proprietary exhaust se alant around pipe joints.
4. Install new gasket to exhaust manifold flange.
5. With assistance, position cata lyst, secure string (x2) to
HEGO multiplugs, feed sensor leads behind heat shield.
Install catalyst to exhaust manifold.
6. Install and torque tighten nuts (x3), catalyst to exhaust manifold.
7. Align centre pipe asembly to catalyst, torque tighten
clamp nuts.
8. Remove string (x2), conne ct multiplugs (x2), HEGO
sensors.
9. Secure sensor lead in clip on heatshield.
10. Install rear exhaust silencer (refer to Workshop Manual procedure 09.00.KA Muffler & Bypass Valve Assembly -
Remove for Access & Refit).
11. Lower vehicle on ramp.
RH Catalyst & Pipe Assembly-Renew
Repair Operation Time (ROT)
Repair Operation Time (ROT)

Pipes and Supports (09.03)
Exhaust System (09.00)
May 2007 Workshop Manual 9-2-1
Exhaust System (09.00)
Pipes and Supports (09.03)
Specifications
Maintenance
RH/LH Catalyst and Pipe Assembly-
Renew
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. Release sensor lead from clip on heatshield.
5. Secure sufficient lengths of string to HEGO sensor multiplugs for assembly purposes.
6. Loosen LH and RH clamp nuts , catalysts to centre pipe.
7. Remove nuts (x3), catalyst to exhaust manifold.
8. With assistance, manoeuvre exhaust centre pipe assembly rearwards to release from catalysts.
9. With assistance, release and support weight of LH/RH catalyst from exhaust manifold.
10. Manoeuvre HEGO sensor le ads and remove cable tie.
Release HEGO sensor leads from behind heat shield.
Remove string from HEGO multiplugs.
11. Remove catalyst assembly.
12. Remove and discard gasket.
13. Remove HEGO sensors (x2) from catalyst.
Installation
1. Clean catalyst, mating joint faces and HEGO sensors.
2. Install and tighten HEGO sensors (x2) to catalyst. 3. Install new gasket to exhaust manifold flange.
4. With assistance, position cata
lyst, secure string (x2) to
HEGO multiplugs, feed sensor leads behind heat shield.
Install catalyst to exhaust manifold.
5. Install and torque tighten nuts (x3), catalyst to exhaust manifold.
6. Align centre pipe assembly to catalyst, torque tighten clamp nuts.
7. Remove string (x2), conne ct multiplugs (x2), HEGO
sensors.
8. Secure sensor lead in clip on heatshield.
9. Install rear exhaust silencer (refer to Workshop Manual procedure 09.00.KA Silencer and Bypass Valve
Assembly - Remo ve for Access and Refit).
10. Lower vehicle on ramp.
Exhaust Centre Pipe-Renew
Removal
1. Raise vehicle on ramp.
2. Remove pipe assembly exha ust rear - RH (refer to
Workshop Manual procedure 09.00. Pipe Assembly -
Exhaust - Rear - RH - Renew).
3. Remove pipe assembly exha ust rear - LH (refer to
Workshop Manual procedure 09.00.JB Pipe Assembly -
Exhaust - Rear - LH - Renew).
4. Loosen clamp nuts (x2), centre pipe to LH and RH catalysts.
5. Release centre pipe from mountings, LH and RH
catalysts, remove centre pipe.
6. Remove bolts (x3), heatshie ld to centre pipe, remove
heatshield.
7. Remove Torx screws (x4), mounting bracket to centre pipe, remove bracket.
Installation
1. Use a proprietary exhaust seal ant around all pipe joints
prior to installation of exhaust system.
2. Install mounting bracket to centre pipe, install and tighten Torx screws (x4).
3. Install heatshield to centre pipe, install and tighten bolts (x3).
4. Apply exhaust sealant to centre pipe joints.
Torque Figures
DescriptionNmlb. / ft.
Catalyst (nuts / bolts) 25.5-34.5 19-25.5
Catalyst (clamps) 19-22 14.5-16.5
Centre pipe to rear pipe (clamp) 39-51 29-38
Rear Pipe to Silencer (bolt) 28-33 21-24.5
Repair Operation Time (ROT)
Attach lengths of string to th e HEGO sensor multiplugs. This
enables routing the HEGO se nsor harness behind the
exhaust heat shield on assembly.
Repair Operation Time (ROT)

May 2007 Workshop Manual 10-1-1
Fuel (10.00)
Contents
Fuel Tank and Lines (10.01) ................................ 10-1-2Description ............................................................. 1-2 Fuel Tank............................................................... 1-3
Fuel Pumps ............................................................ 1-3
Jet Pumps .............................................................. 1-4
Filler Neck and Check Valve .................................. 1-4
Valves and Sensors ................................................. 1-5
Fuel System Schematic ........................................... 1-5
Evaporative Loss System ......................................... 1-6 System Operation .................................................. 1-6
Fuel Tank Vents and Control Valves ....................... 1-6
Safety Precautions .................................................. 1-7
Specifications.......................................................... 1-7
Maintenance ........................................................... 1-8 Fuel System ........................................................... 1-8
Fuel Filter Assembly-Renew .. ................................. 1-8
Fuel Pump and Reservoir Assembly-Renew ............ 1-9
Fuel Tank and Canister Assembly-Renew ............. 1-11
Fuel Tank and Canister Assembly-Remove
for Access/Refit ................................................... 1-13
Fuel Tank Sender Assembly-Renew ...................... 1-15
Fuel Vapour Pipe Assembly-Renew ...................... 1-16
Fuel Supply and Vapour Pipe Assembly-Renew .... 1-17
Manifold Supply Fuel Pipe Assembly- Renew ....... 1-17

Fuel Tank and Lines (10.01)
Fuel (10.00)10-1-8 Workshop Manual May 2007
Maintenance
Fuel System
The fuel system must only be serviced by staff trained in fuel
handling.
Fuel Filter Assembly-Renew
Removal
1. Depressurise the fuel system (see Workshop Manual procedure 10.01.EK Fuel System - Depressurise).
2. Disconnect battery earth lead.
3. Release and remove luggage compartment rear floor carpet.
4. Remove luggage compartment front floor carpet retainers (x6).
5. Remove luggage compartment front floor carpet.
6. Remove fuel tank cover, clean off the sealant around the aperture.
7. Remove nuts (x7) and rele ase fuel tank service cover
and clamp. 8. Install the fuel tank drainage adaptor (see Fig. 1).
9. Connect the external pipe to a fuel recovery unit.
Recover the fuel in accordance with the recovery unit
instructions.
10. Release the fuel filter hoses (x2) quick release unions (see Fig. 2).
Repair Operation Time (ROT)
Warning
Read and follow all fuel handling instructions (at the beginning of the Fuel Syst em section) and the fuel
bowser manufacturers fuel handling documentation
before commencing work on the fuel system. Clean up
spillages immediately and disp ose of fuel contaminated
materials safely.
Warning
Ensure there is adequate ve ntilation inside the vehicle
(i.e. place the vehicle in a we ll ventilated area, with the
windows open).
Warning
Disconnect the battery earth lead before commencing work on the fuel system.
Caution
The following procedure is completed inside the vehicle
cabin area. Extra care must be taken to ensure no fuel or
fuel vapours come into contac t with the vehicle interior.
Fig. 1
Warning
Several litres of fuel remain in the fuel tank sump after
draining.
Fig. 2
$
$

Issue 5, January 2010 Workshop Manual 11-1-1
Steering (11.00)
Contents
Steering Gear (11.01) .......................................... 11-1-2Diagnostics - Symptom Chart................................. 1-2
Specifications.......................................................... 1-4
Power Steering (11.02) ........................................ 11-2-1 Description ............................................................. 2-1
Specifications.......................................................... 2-1
Maintenance ........................................................... 2-2Power Steering System - Bleed ............................... 2-2
Procedure .............................................................. 2-2
Power Steering Pump-Renew ................................. 2-2
Power Assisted Steering (PAS) Rack -
Remove and Install................................................. 2-2
RH/LH Track Rod End-Renew .............................. 2-11
Power Steering Pump to Rack Hose Assembly
-Renew ................................................................ 2-11
Power Steering Rack to Cooler Hose-Renew ........ 2-12
Steering Column (11.04)...................................... 11-4-1 Description ............................................................. 4-1
Specifications.......................................................... 4-1
Maintenance ........................................................... 4-1Top Shroud for the Steering Column
- Remove and Install .............................................. 4-1
Bottom Shroud for the Steering Column
- Remove and Install .............................................. 4-1
Steering Column Gaiter-Renew .............................. 4-2
Upper Steering Column Assembly-Renew .............. 4-3
Top and Bottom Shrouds for the Steering Column
- Remove and Install .............................................. 4-4
Steering Column Lower Shaft Assembly-Renew ...... 4-5
Steering Column Switches (11.05)....................... 11-5-1 Maintenance ........................................................... 5-1Ignition Switch-Renew (Pre-08 MY Only) ............... 5-1
Steering Column Stalk Assembly Switch-Renew
(Pre-08 MY Only) ................................................... 5-1
Cruise Control Switch-Renew................................. 5-2
Indicator Switch for the Steering Column
- Remove and Install .............................................. 5-2
Airbag Rotary Coupler Assembly - Remove and
Install ..................................................................... 5-2
Wiper Switch for the Steering Column
- Remove and Install .............................................. 5-4
Steering Wheel (11.06) ........................................ 11-6-1 Specifications.......................................................... 6-1
Maintenance ........................................................... 6-1Steering Wheel-Renew .......................................... 6-1
Driver’s Airbag Module - Remove and Install .......... 6-1

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

Steering Column (11.04)
Steering (11.00)
Issue 4, November 2008 Workshop Manual 11-4-1
Steering (11.00)
Steering Column (11.04)
Description
The steering column has reach and tilt functions. These let
the driver manually set the position of the steering column.
by using the reach / tilt lever that is on the underside of the
steering column.This is indepe ndent of the ignition switch
position .
The steering intermediate shaft has two parts. The lower
shaft is attached to both th e steering gear and the upper
shaft.
The Electronic Steering Column Lock (ESCL) is attached to
the upper casting of the steering column and has a locking
pin. The steering column is electrically unlocked when the
ignition key is installed and operated to position 2. The lock
engages when the ignition switch is removed and the
steering wheel is turned to the centre position.
Specifications
Maintenance
Top Shroud for the Steering Column -
Remove and Install
Remove
1. Release the steering column adjustment lever.
2. Move the steering wheel to the longest column position.
3. Push the adjustment lever back to lock the steering
wheel.
4. Release the seven clips and remove the lower panel from the driver’s side of the instrument panel.
For Pre-08MY vehicles:
5. Put the key in the ignition switch and turn it to position 1 to release the Electronic Steering Column Lock (ESCL).
For 08MY vehicles or newer:
6. Put the Emotion Control Unit (ECU) into the docking station at position 2 to release the ESCL. 7. Turn the steering wheel to get access to the top screw in
the front face of the shroud at the left side .
8. Remove the screw.
9. Turn the steering wheel to get access to the top screw in the front face of the shroud at the right side .
10. Remove the screw.
11. Remove the top shroud.
Install
1. Put the top shroud in position on the steering column.
For Pre-08MY vehicles:
2. Put the key in the ignition switch and turn it to position1 to release the Electronic Steering Column Lock (ESCL).
For 08MY vehicles or newer:
3. Put the Emotion Control Unit (ECU) into the docking station at position 2 to release the ESCL.
4. Turn the steering wheel to get access to the top screw hole in the front face of the shroud at the left side.
5. Install the screw.
6. Turn the steering wheel to get access to the top screw hole in the front face of the shroud at the right side.
7. Install the screw.
Bottom Shroud for the Steering Column -
Remove and Install

Remove
1. Release the seven clips and remove the lower panel from the driver’s side of the instrument panel.
For Pre-08MY vehicles:
2. Put the key in the ignition switch and turn it to position 1 to release the Electronic Steering Column
Lock (ESCL).
For 08MY vehicles or newer:
3. Install the Emotion Control Unit (ECU) into the docking station at position 2 to release ESCL.
4. Turn the steering wheel to get access to the two screws in the front face of the shrouds at the left side (refer to
Figure 1).
Torque Figures
DescriptionNm.lb/ftNominal
Steering Column to cross
car beam 21-27 15.5-
19.924Nm
Upper column to I-shaft 27.3- 32.720-24.1 30Nm
Vee-yoke to pinion
extension shaft 15.5-
18.511.4-
21.217Nm
Power coupling to pinion 21.2- 28.815.6-
21.225Nm
Repair Operation Time (ROT)
Note: The top screw goes thro
ugh the top shroud and a tab
on the bottom shroud to attach it.
Note: The top screw goes thro ugh the top shroud and a tab
on the bottom shroud to attach it.
Repair Operation Time (ROT)