coolant ASTON MARTIN V8 VANTAGE 2010 Workshop Manual

Safety Precautions
Issue 5, January 2010 Workshop Manual 0-0-7
Safety Precautions
All service workshops are a source of potential danger and
repair work should only be performed by technically trained
staff following procedures detailed in this manual. A safety
conscious approach to the performance of all service
procedures must be observed at all times. Statutory
requirements governing all aspects of health and safety at
work including directives for the proper use of materials and
equipment must be implemented.
The following contains a list of particular safety precautions
which should be observed; it is not intended to be
exhaustive.
Battery Disconnection
When a service manual procedure requires the vehicle
battery to be disconnected - always physically disconnect
the vehicle battery earth (Negative) lead.
Do not use the ‘Battery Disconnect Switch’.
After reconnecting the vehicle battery the following items
will have to be reset or re-learnt:
•Radio pre-sets
•Windows
• DTCs will be lost
Air Conditioning (A/C) System
Do not break into the A/C refrigeration system until the
refrigerant has been evacuated using the procedure detailed
in this manual. Do not disconne ct any A/C refrigerant system
pipes unless trained and instructed to do so. The refrigerant
used can cause blindness if allowed to contact your eyes.
Chemical Handling and Storage
Chemicals used in the servicing of motor vehicles include
acids, adhesives, antifreeze, brake fluids, coolants, grease,
oil, paint, resin and solvents. Exposure to certain chemicals
through direct contact or inhalation can be fatal.
Potential hazards may also be present through the incorrect
use, storage and handling of chemicals causing a fire risk.
The following precaution s should be observed.
• Strictly adhere to handling and safety information found on containers and labels.
• Do not store chemicals in unlabelled or incorrectly labelled containers.
• Containers used for storing chemicals should not be left open; there is a risk of spilling , or evaporation of fumes
which may be inflammable or toxic.
• Do not mix chemicals unless instructed to do so following manufacturers guidelines.
• Do not inhale chemical materials to determine identity, they may be toxic.
• Do not use petrol, kerosene, diesel fuel, gas oil, thinners or solvents for washing skin.
• Containers whose capacity is over 25 litres (5 gallons) require a bund wall in order to contain spillages. • Chemicals based on solvents such as paint should not be
sprayed in a confined space; work areas used for such
operations should be well ve ntilated and fume extraction
equipment should be utilised.
• Ensure that adequate ventilation is provided when volatile de-greasing agents are being used.
• Avoid splashing the skin, eyes and clothing .
• Clean chemicals from the skin and clothing as soon as
possible after soiling .
• Wear protective clothing such as goggles, non porous gloves and apron when handling battery acid and other
corrosive and toxic substances.
Electrical Equipment
• Ensure that electrical equipment is in safe working order before use.
• Inspect power leads of all mains electrical equipment for damage and security, and check that it is properly earthed.
• Ensure that electrical equipment is protected by a fuse of the correct current rating .
• Disconnect the battery before commencing repair operations to the electrical sy stem, fuel system and engine
or when working beneath the vehicle.
Exhaust Fumes
Engines should not be run in confined spaces as exhaust
fumes contain harmful and to xic substances including
carbon monoxide which can prove fatal if inhaled. Engines
must only be run where there is fume extraction equipment
in operation or where there is adequate ventilation.
Fire Precautions
• Ensure that a suitable form of fire extinguisher is conveniently located near the work area.
• Keep oils, solvents and combustible materials away from naked flames and other sources of ignition.
• Ensure that NO SMOKING signs are posted around areas where combustible materials and vapour may be present
and ensure that the warnings are strictly observed.
• Ensure that dry sand is availabl e to soak up any spillage of
fuel or other flammable solutions.
• Fume extraction equipment must be available and in full working order to remove combustible and toxic vapours.
• All personnel should be aware of the fire drill procedures and precautions. WAR NI NG
DO NOT SMOKE IN THE VICINITY OF VOLATILE DE- GREASING AGENTS.
WAR NI NG
FUME EXTRACTION EQUIPMENT MUST BE IN
OPERATION WHEN SOLVENTS ARE USED E.G. TRICHLOROETHANE, WHITE SPIRIT, SBP3,
METHYLENE CHLORIDE, PERCHLORETHYLENE.

Front End (01.02)
Body System (01.00)1-2-6 Workshop Manual Issue 5, January 2010
16. Remove hood/wing weathers trip (see Figure 12).
Installation
1. Install hood/wing weatherstrip.
2. Install sound deadening pads.
3. Install side strake (screw x1, nut x1) - glued.
4. Install vent mesh (nuts x3).
5. Install side repeater lamp body.
6. Install wing and refit clips (x2) wing to sill.
7. Install screw, wing to sill.
8. Install nut and bolt, wing to sill.
9. Install bolts and spacers (x2) under wing.
10. Connect side repeater lamp.
11. Install bolt and spacer (A-post top).
12. Install bolts and spacers (x4) wing to body top fixings.
13. Install slam panel (screws x12).
14. Install door (see Workshop Manual procedure 01.03.EA
Door Assembly - RH - Remove for Access and Refit).
15. Install Cover Assembly - Fr ont Bumper (see Workshop
Manual procedure 01.19.AA Cover Assembly - Front
Bumper - Renew).
LH Front Wing Panel Assembly - Renew
Removal
1. Remove Cover Assembly - Fr ont Bumper (see Workshop
Manual procedure 01.19.AA Cover Assembly - Front
Bumper - Renew).
2. Remove door (see Workshop Manual procedure 01.03.FA Door Assembly - LH - Remove for Access and
Refit).
3. Remove slam panel (screws x12).
4. Unclip hood ground lead (clips x2). 5. Remove bolts and spacers (x4) wing to body top fixings
(see Figure 1).
6. Remove bolt and spacer (A-post top) (see Figure 2).
7. Move coolant catch tank aside (bolts x2 and sound deadening) (see Figure 3).
Figure 12
Repair Operation Time (ROT)
A0102158
Figure 1
Figure 2
Figure 3
A0102154
A0102155
A0102156

Front End (01.02)
Body System (01.00)1-2-8 Workshop Manual Issue 5, January 2010
15. Remove vent mesh (nuts x3) (see Figure 10).
16. Remove side strake (nut x1) glued (see Figure 11).
17. Remove sound deadening pads (x2).
18. Remove hood/wing weathers trip (see Figure 12).
Installation
1. Install hood/wing weatherstrip.
2. Install sound deadening pads.
3. Install side strake (screw x1, nut x1) - glued.
4. Install vent mesh (nuts x3).
5. Install side repeater lamp body.
6. Install wing and refit clips (x2) wing to sill.
7. Install screw, wing to sill. 8. Install nut and bolt, wing to sill.
9. Install bolts and spacers (x2) under wing.
10. Connect side repeater lamp.
11. Install coolant catch tank (bolts x2 and sound
deadening).
12. Install bolt and spacer (A-post top).
13. Install bolts and spacers (x4) wing to body top fixings.
14. Clip hood ground lead.
15. Install slam panel (screws x12).
16. Install door (see Workshop Manual procedure 01.03.FA
Door Assembly - LH - Remove for Access and Refit).
17. Install Cover Assembly - Front Bumper (see Workshop
Manual procedure 01.19.AA Cover Assembly - Front
Bumper - Renew).
Figure 10
Figure 11
Figure 12
A0102159
A0102159A
A0102158

Instrument Panel (IP) (01.12)
Body System (01.00)
Issue 5, January 2010 Workshop Manual 1-9-1
Body System (01.00)
Instrument Panel (IP) (01.12)
Specifications
Maintenance
Instrument Panel - Renew
Removal
1. Disconnect vehicle battery.
2. Drain cooling system (see Workshop Procedure 03.03.AD Coolant - Drain and Refill).
3. Evacuate air conditioning system (see Workshop Procedure 12.03.FA Tank - Receiver Drier - Renew).
4. Remove RH door (see Work shop Procedure 01.03.EA
Door Assembly - RH - Remo ve for Access and Refit).
5. Remove LH front seat (see Workshop Manual 01.10.AB
Seat Assembly - Front - LH - Remove for Access and
Refit).
6. Remove RH front seat (see Workshop Manual 01.10.AA Seat Assembly - Front - RH - Remove for Access and
Refit). 7. Remove tread plate badges - screws x2 (see Figure1).
8. Remove screws (x12) 6 each
side and remove LH and
RH side tread plates.
9. Release door seal from d oor aperture (see Figure 2).
Torque Figures
DescriptionNm
IP Mountings 22.5
Glue pot bolts 8
Blower motor to bulkhead 10-14
Repair Operation Time (ROT)
01-12-013
Figure 1
Figure 2

Instrument Panel (IP) (01.12)
Body System (01.00)
Issue 5, January 2010 Workshop Manual 1-9-5
37. Manoeuvre and remove inst rument panel sufficient to
gain access to heater hose (see Figure 17).
38. Position container to collect coolant.
39. Release clip and disconne ct hose from heater unit.
40. Disconnect condenser hose from heater unit.
41. Manoeuvre and remove inst rument panel from vehicle
(see Figure 18).
42. Remove container.
Installation
1. With assistance, manoeuvre instrument panel into vehicle.
2. Connect condenser hose to heater unit.
3. Connect hose to heater and secure with clip.
4. With assistance, manoeuvre instrument panel into position aligning upper column to intermediate shaft.
5. Install new upper column pinch bolt (do not torque at this stage).
6. Install bolts (x6) through instrument panel to both A- posts (do not torque at this stage). 7. Install screws (x4) through
instrument panel to bulkhead
(do not torque at this stage).
8. Ensure instrument panel is correctly aligned and tighten screws (x4) and bolts (x6) to correct torque.
9. Loosen and release attachme nts from instrument panel
and with assistance, remove tool (501-F116) from
vehicle.
10. Tighten upper column pinch bolt to correct torque.
11. Install gaiter to bulkhead.
12. Connect multiplugs (x14) fr om instrument panel to main
body harness.
13. Apply adhesive and install instrument panel upper air
vents and secure in clips.
14. Position drivers side lower instrument panel and connect air temperature pipe.
15. Install panel in clips (x7).
16. Install steering column upper and lower shrouds and install and tighten screws (x7).
17. Install steering wheel (see Workshop Manual 11.06.AB Steering Wheel Renew).
18. Install and tighten bolt from heater fan to bulkhead.
19. Install and torque tighten bolts (x2) from instrument panel to tunnel.
20. Install footwell carpet.
21. Install drivers side carpet retaining plate to bulkhead.
22. Install and torque tighten Allen bolts (x4).
23. Install gear lever mechanism and install and tighten screws (x6).
24. Install selector cable ball joints to gear lever mechanism.
25. Install centre column switch panel and connect multiplugs (x8).
26. Install rear centre cons ole (see Workshop Manual
01.04.BB Centre Console Rear Renew).
27. Install LH and RH cant rail trim panels and install and tighten screws (x4).
28. Install trim finishers (x4) and install seals to door aperture.
29. Connect multiplugs (x11) from LH and RH A-post to
instrument panel.
30. Connect fuel filler flap release switch.
31. Install LH and RH A-post trim panels.
32. Install LH and RH A-post door trim plates.
33. Install rivets (x2), insta ll and tighten screws (x2).
34. Install seal to door aperture.
35. Install LH and RH side tread plates and tighten screws (x12).
36. Install LH and RH side tread plate badges and tighten screws (x4).
37. Install RH door (see Workshop Manual 01.03.EA Door Assembly - RH - Remove for Access and Refit).
38. Install RH front seat (see Workshop Manual 01.10.AA Seat Assembly - Front - RH - Remove for Access and
Refit).
Figure 17
Figure 18

Instrument Panel (IP) (01.12)
Body System (01.00)1-9-6 Workshop Manual Issue 5, January 2010
39. Install LH front seat (see Workshop Manual 01.10.AB Seat Assembly - Front - LH - Remove for Access and
Refit).
40. Fill cooling system (see Workshop Manual 03.03.AD
Coolant - Drain and Refill).
41. Re-charge air conditioni ng system (see Workshop
Manual 12.03.FA Tank - Receiver Drier - Renew).
42. Connect vehicle battery.
Airbag Panel and Door Assembly -
Renew
Removal
1. Remove glovebox assembly (see Workshop Manual
procedure 01.12.AL Glovebox Assembly - Renew).
2. Remove glovebox shield (see Figure 1).
3. Remove the bolts (x3) that secure the airbag panel and
door assembly plate to the chassis (see Figure 2)
.
4. Remove airbag panel and d oor assembly (5 clips) (see
Figure3).
Installation
1. Install airbag panel and door assembly (5 clips).
2. Through glovebox aperture, install support right-angled bar and secure bolts (x3).
3. Remove and clean double-sided taped from glovebox shield, apply new tape and install.
4. Install glovebox assembly (see Workshop Manual procedure 01.12.AL Gloveb ox Assembly - Renew).
Glovebox Assembly - Renew
Removal
1. Remove passenger lower panel assembly (5 clips and
multiplug).
2. Remove the securing screws holding the glove box hinge to the chassis (x2).
3. Support the glove box and locate the latch mechanism.
4. Using a suitable tool press the latch mechanism to release the glove box.
5. Support the glove box and detach the buffer cord from the glove box.
Installation
1. Support glovebox and attach the buffer cord (ensure the cord is through correct aperture).
2. Install glovebox into aperture and press top to latch.
3. Align the glovebox hinge an d secure with screws (x2)
including spacers between the hinge and chassis.
4. Install passenger lower panel assembly (5 clips and 1 multiplug).
Repair Operation Time (ROT)
Figure 3
Repair Operation Time (ROT)
ItemCode
Glovebox Assembly-Renew 01.12.AL

Issue 5, January 2010 Workshop Manual 3-0-1
Engine System (03.00)
Contents
Engine Assembly (03.00) ....................................... 3-0-3Description ............................................................. 0-3
Maintenance ........................................................... 0-4Engine Assembly-Renew ........................................ 0-4
Engine Assembly-Remove for Access and Refit ....... 0-4
Engine Structure (03.01) ........................................ 3-1-1 Description ............................................................. 1-1Engine Block .......................................................... 1-1
Cylinder Block Drain Plug ...................................... 1-2
Knock Sensors........................................................ 1-3
Bedplate ................................................................ 1-3
Engine Mountings .................................................. 1-3
Cylinder Heads ...................................................... 1-4
Inlet/Exhaust Manifolds .......................................... 1-4
Specifications.......................................................... 1-4
Maintenance ........................................................... 1-5 Upper Intake Manifold Assembly (LHD) - Renew ... 1-5
Upper Intake Manifold Asse mbly (RHD) - Renew ... 1-6
Upper Intake Manifold Assembly Gasket (LHD)
- Renew ................................................................. 1-8
Upper Intake Manifold Assembly Gasket (RHD)
- Renew ................................................................. 1-9
Intake Manifold Assembly - Remove for Access
and Refit (With Engine Removed)......................... 1-11
RH/LH Cylinder Head Gasket - Renew................. 1-12
RH/LH Cylinder Head - Overhaul ........................ 1-13
Cylinder Head (Engine Set) - Overhaul ................. 1-14
Valve Set (Engine Set) - Renew
(including de-coke) .............................................. 1-15
Inlet Valve (Set) - Renew ...................................... 1-16
Exhaust Valve (Set) - Renew ................................. 1-16
Spring (Valve Set) - Renew ................................... 1-17
Spring (Inlet Valve Set) - Renew ........................... 1-18
Inlet and Exhaust Valve Seal (Engine Set) - Renew 1-19
Spring (Valve Exhaust Set) - Renew....................... 1-19
RH/LH Cylinder Head Gasket - Renew (with
Engine Removed) ................................................. 1-20
Cylinder Head Gasket (E ngine Set) - Renew (with
Engine Removed) ................................................. 1-21
Lubrication System (03.02) .. .................................. 3-2-1
Dry Sump System .................................................. 2-1
Specifications.......................................................... 2-2 Engine Oil Specification ......................................... 2-2
Maintenance ........................................................... 2-2 Oil Pressure Pump to Sump Gasket - Renew .......... 2-2
Oil Pump Chain - Renew ....................................... 2-2
Oil Sump Pan - Renew........................................... 2-3
Oil Sump Pan - Remove and Reseal ....................... 2-5
Oil Cooler - Renew ................................................ 2-8
Oil Cooler Tank Assembly - Renew ........................ 2-9
Thermostat - Renew ............................................... 2-9
Oil Cooler Tank Pipe Assembly - Renew .............. 2-10
Oil Thermostat to Tank Tube Assembly - Renew .. 2-10
Oil Pump Inlet Tube Assemb ly - Renew ............... 2-11 Oil Pump Inlet Tube Assembly - Renew ............... 2-12
Oil Pump Outlet Tube Asse
mbly - Renew ............ 2-12
Oil Thermostat Cooler Pipe Assembly - Renew .... 2-13
Oil Temperature Controller - Renew .................... 2-14
Oil Sump Pan - Renew (with Engine Removed) .... 2-14
Oil Sump Pan - Remove and Reseal
(with Engine Removed) ........................................ 2-17
Cooling System (03.03) ......................................... 3-3-1 Description ............................................................. 3-1Water Pump .......................................................... 3-1
Thermostat ............................................................ 3-1
Radiator................................................................. 3-1
Cooling Fans .......................................................... 3-1
Coolant Reservoir .................................................. 3-1
Engine Oil Cooler .................................................. 3-2
Specifications......................................................... 3-2
Torque Figures ....................................................... 3-2
Maintenance ........................................................... 3-2 Coolant-Drain/Fill .................................................. 3-2
Thermostat - Renew............................................... 3-3
Water Pump - Renew ............................................ 3-3
Water Pump Pulley - Renew .................................. 3-3
Oil Temperature Controller - Renew ...................... 3-4
Radiator Fan and Motor Assembly - Remove and
Install ..................................................................... 3-4
Radiator and Condenser Assembly - Renew ........... 3-5
Radiator Assembly - Renew.................................... 3-5
Air Conditioning Condenser - Renew ..................... 3-6
Radiator Fan Modulator - Remove and Install......... 3-6
Expansion Tank Assembly - Renew ........................ 3-6
Coolant Recovery Tank Assembly - Remove and
Install ..................................................................... 3-7
Engine Coolant Reservoir Hose - Renew ................ 3-8
Water Inlet/Outlet Manifold - Renew ..................... 3-8
Engine Electric Coolant Temperature Sensor
- Renew ............................................................... 3-10
Thermostat Cover - Renew .................................. 3-11
Fuel Charging System (03.04)................................ 3-4-1 Safety Precautions .................................................. 4-1
Maintenance ........................................................... 4-2Fuel Rails - Renew ................................................. 4-2
Fuel Injection Pressure Sensor - Renew .................. 4-3
Fuel Temperature Sensor - Renew ......................... 4-3
Fuel Injector Engine Set - Renew............................ 4-4
Fuel Injector - Each - LH Bank - Renew.................. 4-5
Fuel Injector - Each - RH Bank - Renew ................. 4-5
Engine Set - Fuel Injector - LH Bank - Renew ......... 4-6
Engine Set - Fuel Injector - RH Bank - Renew......... 4-6
Accessory Drive System (03.05) ............................ 3-5-1 Description ............................................................. 5-1Auxiliary Drives...................................................... 5-1
Automatic Belt Tensioner ....................................... 5-1
Specifications ......................................................... 5-1
Maintenance ........................................................... 5-1

Engine Assembly (03.00)
Engine (03.00)3-0-6 Workshop Manual Issue 5, January 2010
7. Remove throttle body duct for access (clips x3) (refer to Figure 2).
Suspension Removal
8. Remove RH wheel arch liner (refer to Workshop Manual procedure 01.02.GB Wheel Arch Liner - Front - RH -
Renew).
9. Remove LH wheel arch liner (refer to Workshop Manual procedure 01.02.FB Wheel Arch Liner - Front - LH -
Renew).
10. Remove road wheel/s.
11. Remove brake callipers (tie aside).
12. Remove brake discs.
13. Remove anti-roll bar from links (nuts x2).
14. Remove front springs and da mpers (refer to Workshop
Manual procedure 04.03.AA Spring and Damper
Assembly - Front Pair - Renew).
15. Disconnect track rod ends.
16. Remove level sensor link from bottom arm (nut x1).
17. Mark lower arm bolt and washer positions (to retain geometry).
18. Remove bottom arms (nut and bolt x4) with uprights and top arm.
19. Disconnect level sensor multiplug.
Cooling Removal
20. Drain coolant (refer to Workshop Manual procedure 03.03.AD Coolant - Drain and Refill). 21. Disconnect top hose and unclip from body (refer to
Figure 3).
22. Disconnect bottom hose and tie aside (refer to Figure 4).
23. Disconnect expansion tank to engine hose (quickfit).
24. Disconnect heater feed hose (quickfit) (refer to Figure
5).
Figure 5
Figure 2
$3#
Figure 3
Figure 4
$3#
$3#
$3#

Engine Assembly (03.00)
Engine (03.00)
Issue 5, January 2010 Workshop Manual 3-0-11
9. Connect bottom hose (refer to Figure 22).
10. Connect expansion tank to engine hose.
11. Connect heater feed hose (quickfit) (refer to Figure 23).
12. Connect heater return hose (quickfit).
13. Connect expansion tank to engine (bleed) hose and body clips (x2).
14. Refill coolant (refer to Workshop Manual procedure 03.03.AD Coolant - Drain and Refill).
Booster Hose Install
15. Install vacuum hose to booster.
P.A.S. Install
16. Connect H.P. pipe to pump (renew O-ring).
17. Install PAS reservoir to bracket (bolt x1). 18. Install hoses (x2) to PAS reservoir (refer to Figure 24).
19. Install suction hose to body P-clip (bolt x1).
20. Install pipes to steering rack
(bolt x1) and fit new O-rings
(x2).
Oil Tank Install
21. Connect oil pipe from oil thermostat.
22. Install oil tank (bolts x4) (refer to Figure 25).
Figure 22
Figure 23
$3#
$3#
Figure 24
Figure 25
$3#
$3#

Engine Structure (03.01)
3-1-2Workshop ManualIssue 4, November 2008
Figure 2 - Cylinder Numbers
Cylinder Block Drain Plug
The coolant drain plug is on the rear left side of the cylinder block.
On vehicles that have a cold climate package (for example: vehicles that operate in conditions regularly below -30°C) a
cylinder block heater unit is installed instead of the drain plug (Refer to Figure 3).
Figure 3 - Cylinder Block Heater
E 43432