coolant reservoir ASTON MARTIN V8 VANTAGE 2010 Workshop Manual

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)
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#

Cooling System (03.03)
Engine (03.00)
Issue 5, Janauary 2010 Workshop Manual 3-3-1
Engine (03.00)
Cooling System (03.03)
Description
The water pump is of a conventional design and is located at
the front of the engine. It is driven by the accessory drive
belt.
Thermostat
The thermostat allows rapid en gine warm-up by redirecting
coolant flow through the engine below 88 °C (190.5°F).
The thermostat also assists in keeping the engine operating
temperature within predetermi ned limits. The thermostat
starts to open between 86°C - 90°C (186.8°F - 194°F) and is
fully open at 102°C (215.5°F).
Cold Engine (Bypass Circuit) - When the engine is cold and
the thermostat is closed coolant flows from the water pump
through the engine block, through the cylinder heads and
into the water cross-over housing. Coolant then passes
through the secondary thermostat sealing plate and returns
to the water pump.
Warm Engine (Cooling Module Circuit) - When the engine
is warm and the thermostat is open coolant flows from the
water pump, through the engine block, through the cylinder
head and into the water cros s-over housing. Coolant then
passes through the upper coolant hose, through the radiator and returns to the water pump through the lower coolant
hose and water cross-over housing.
Radiator
The radiator is of aluminium construction with plastic end
tanks. Foam seals are installed to the radiator to prevent the
cooling air from by-passing the radiator core. The radiator is
located by four isolator mo
untings and supported by the
radiator support beams. A coolant drain plug is provided in
the lower right-hand side for the draining of the coolant. The
cooling fan shroud is attached to the radiator.
Cooling Fans
Two variable speed electric cooling fans are housed in the
cooling fan pack for the cooling of the radiator. The speed of
the electric cooling fans is adjusted by the Powertrain
Control Module (PCM).
Coolant Reservoir
A pressurised coolant reservoir system is used which
continuously removes any air from the cooling system. A
continuous vent from the engine and radiator to the coolant
expansion tank prevents air locks from forming in the
•Water pump
• Thermostat
•Radiator
• Pressure cap
• Coolant Reservoir
• Electric cooling fans (x2)
• Cooling fan motor control module
• Engine oil cooler
Radiator
Cooling Fans
Thermostat
Coolant Reservoir Engine Oil Cooler
Cooling Fan
Control Module
Water Pump
Coolant Recovery Pressure Cap
03-03-001

Cooling System (03.03)
Engine (03.00)3-3-2 Workshop Manual Issue 5, Janauary 2010
cooling system. No manual bleed points are provided on the
system.
The coolant reservoir should be full when the coolant system
is cold.
Engine Oil Cooler
The oil temperature is contro lled by an air/oil cooler
mounted at the front of the car. Engine oil is removed from
the dry sump, with the scavenge pump. The oil is routed to
a temperature controlled thermostat which controls the
directional flow of the oil. With the thermostat closed the oil
is routed directly to the oil tank. When the thermostat starts
to open (at 105°C) the oil is routed via the air/oil cooler
before entering the tank.
Specifications
Torque Figures
Maintenance
Coolant-Drain/Fill
1. Raise vehicle on ramp.
2. Remove front undertray (refer to Workshop Manual procedure 01.02.NB Undertray - Front - Renew).
3. Position suitable container to collect coolant.
4. Remove pressure cap from coolant reservoir.
5. Remove drain plug from radiator, allow coolant to drain.
6. Installation
7. Clean radiator drain plug.
8. Install and tighten drain plug.
9. Remove drain container.
10. Install front undertray (refer to Workshop Manual procedure 01.02.NB Undertray - Front - Renew).
11. Lower vehicle on ramp.
12. Fill cooling system with specified coolant mix to maximum level in coolant reservoir.
Antifreeze Mix
50% OAT coolant/50% water
Pressure Cap 150kpa
Leakage Rates 30cm/min. 150-180kpa
60xcm/min. 10kpa
Up to 75kpa @ 150cm/h
Water Pump Pumps 4ltr/min. @ 1000rpm
Pumps 240ltr/min. @ 7000rpm
Thermostat Opens between 86°C - 90°C (186.8°F -
194°F)
Fully open at 102°C
The anti-freeze is un ique and cannot be mixed with other
anti-freeze solutions. The OAT coolant/water mixture has a
life of 150,000 miles or 5 years (which ever comes first).
Description Nm. Ib/ft
Condenser A/C pipes 8-10 6-8
Thermostat Housing 8-12 6-9
Thermostat housing support bracket 23-27 17-20
Water pump 23-27 17-20
Water pump pulley 23-27 17-20
Oil Cooler 50 36
Caution
‘Spring-band’ clips
‘Spring-band’ clips must be installed as detailed below:
All coolant hoses and spigots must be de-greased before assembly.
Repair Operation Time (ROT)
ItemCode
Coolant-Drain-Fill 03.03.AD
WAR NI NG
DO NOT REMOVE THE PRESSURE CAP WHEN THE
COOLANT IS HOT. ALLOW TIME FOR THE COOLANT /
ENGINE TO COOL. TAKE PARTICULAR CARE TO AVOID BURNS FROM THE COOLING SYSTEM.
03-03-002
3
2
4
Coolant Hose SpigottAlignment Marks

Cooling System (03.03)
Engine (03.00)3-3-8 Workshop Manual Issue 5, Janauary 2010
Engine Coolant Reservoir Hose - Renew
Removal
1. Drain cooling system (refer to Workshop Manual procedure 03.03.AD Coolant - Drain and Refill).
2. Remove screw and nut that attaches the expansion tank to body, move expansion tank aside (to access hose
clip).
3. Release clip and disconnect hose from expansion tank.
4. Remove hose from engine (quickfit).
5. Release hose from body clip, remove hose.
Installation
1. Install hose, secure in body clip.
2. Install hose to expansion tank, secure with clip.
3. Install and secure hose to engine (quick fit).
4. Install and torque tighten screw and nut that attaches the expansion tank to body.
5. Refill cooling system (refer to Workshop Manual procedure 03.03.AD Coolant - Drain and Refill).
Water Inlet/Outlet Manifold - Renew
Removal
1. Remove reservoir bracket assembly - vacuum system (refer to Workshop Manual procedure 03.08.AE
Reservoir and Bracket Assembly - Vacuum System -
Renew).
2. Disconnect bottom hose (cli p x1) (refer to Figure 1).
Figure 1
3. Disconnect top hose (clip x1) (refer to Figure 2).
Figure 2
Repair Operation Time (ROT)Repair Operation Time (ROT)
ItemCode
Water Inlet/Outlet Manifold - Renew LHD03.03.MH
Water Inlet/Outlet Manifold - Renew RHD03.03.MJ
A030361
A030361A

Cooling System (03.03)
Engine (03.00)3-3-10 Workshop Manual Issue 5, Janauary 2010
12. Remove coolant manifold (bolts x4) (refer to Figure 9).
Figure 9
13. Remove old seals.
14. Remove bracket breather (bolt x1, nut x2).
Installation
1. Install bracket breather (bolt x1, nuts x2) (torque).
2. Clean gasket faces.
3. Install new seals.
4. Install coolant manifold (bolts x4) (torque).
5. Install 4th bolt of vacuum tank bracket fixing (torque).
6. Install harness clips (x2).
7. Connect coolant temp multiplug.
8. Connect separator hose (clip x1).
9. Connect breather hose (quickfit).
10. Connect heater return hose (clip x1).
11. Connect heater feed hose (clip x1).
12. Connect expansion tank feed hose (quickfit).
13. Disconnect top hose (clip x1).
14. Connect bottom hose (clip x1).
15. Install reservoir bracket asse mbly - vacuum system (refer
to Workshop Manual procedu re 03.08.AE Reservoir and
Bracket Assembly - Vacuum System - Renew).
Engine Electric Co olant Temperature
Sensor - Renew
Removal
1. Drain Cooling system (refer to Workshop Manual procedure 03.03.AD Coolant - Drain and Refill).
2. Disconnect breather pipe qu ickfits (x2) from air cleaner
duct.
3. Remove throttle body duct for access. (clips x3). 4. Remove pump pulley bolts (x3) (refer to Figure 1).
Figure 1
5. Release tensioner and slip belt from idler (refer to Figure
2).
Figure 2
6. Remove pump pulley.
7. Disconnect throttle body coolant hose (refer to Figure 3).
Figure 3
Repair Operation Time (ROT)
A030368A030350
A030553
A030364

Brake Actuation System (06.06)
Brake System (06.00)
May 2007 Workshop Manual 6-6-3
7. Fill reservoir.
8. Bleed Brakes (see Workshop Manual procedure 06.06.AD Pad Kit - Manual Brake and Clutch Pedal -
Renew).
LHD-Brake Master Cylinder Assembly-
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 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 06.06.AD Pad Kit - Manual Brake and Clutch Pedal -
Renew).
10. Top-up coolant.
Clutch Master Cylinder Assembly-Renew
Removal
1. Move drivers seat fully rearward.
2. Remove clevis pin and clip.
3. Remove cylinder securing nuts (x2).
4. Remove fluid (syringe) from brake master cylinder to
below clutch level.
5. Remove corner cross brace.
6. Move expansion tank aside for access (bolt x1, nut x1, hose clips x2, multiplug x1).
7. Disconnect clutch reservoir feed pipe.
8. Disconnect clutch pipe quick fit (pull clip back) and move aside.
9. Remove cylinder assembly.
10. Remove and discard O-ring seal from master cylinder.
11. Split components
12. Remove pipe from cy linder (mark position).
Repair Operation Time (ROT)
Repair Operation Time (ROT)

Brake Actuation System (06.06)
Brake System (06.00)
6-6-4 Workshop Manual May 2007
13. Re-fit components
14. Install pipe to cylinder.
Installation
1. Install new O-ring seal on master cylinder.
2. Install cylinder assembly.
3. Connect pipe to master cylinder (quickfit).
4. Connect clutch reservoir feed pipe.
5. Install expansion tank aside (bolt x1, nut x1, hose clips x2, multiplug x1).
6. Install corner cross brace (torque) (only fully tighten when vehicle on level floor).
7. Install cylinder retaining nuts (x2) (torque).
8. Install clevis pin and clip.
9. Bleed clutch system (see Workshop Manual procedure 08.00.AF - Clutch Hydraulic System - Bleed).
10. Top-up coolant.
RH/LH Front Caliper Hose Assembly-
Renew
Removal
1. Raise vehicle on ramp.
2. Remove road wheel(s).
3. Remove RH/LH front wheel arch liner (see Workshop
Manual procedure 01.02.FB/01.02.GB Wheel Arch
Liner - Front - RH/LH - Renew).
4. Remove bleed nipple dust caps.
5. Position bleed container, connect bleed hose to RHR/ LHR Caliper, open bleed nipples (x1).
6. Position bleed container, connect bleed hose to RHF/ LHF Caliper, open bleed nipples (x1).
7. Depress brake pedal >60 mm and secure with support. 8. Tighten RHR/LHR bleed nipple, disconnect bleed hose,
remove bleed container and fit dust cap.
9. Tighten RHF/LHF bleed nipple, disconnect bleed hose, remove bleed container and fit dust cap.
10. Loosen and disconnect RH/LH front brake tube union from in line connector (see Fig. 1 - RHS shown).
11. Loosen and disconnect RH/LH front brake tube union from hose connection.
12. Release brake tube from clips (x2), remove brake tube.
Installation
1. Install brake tube, connect unions, secure brake tube in clips (x2), torque tighten unions.
2. Install RH/LH front wheel arch liner (see Workshop Manual procedure 01.02.FB/01.02.GB Wheel Arch
Liner - Front - RH/LH - Renew).
3. Remove pedal support.
4. Top-up brake fluid.
5. Bleed brake Caliper with assistance.
6. Remove bleed bottle.
7. Install bleed nipple dust caps.
8. Clean off excess fluid.
9. Top-up brake fluid.
10. Install road wheel(s)).
11. Lower vehicle on ramp.
Repair Operation Time (ROT)
Caution
Always plug pipe ends to prevent ingress of dirt or
moisture into the system.
Fig. 1
A0606125

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)

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)