fuel cap 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.

Engine Structure (03.01)
3-1-12Workshop ManualIssue 4, November 2008
6. Install new gasket on exhaust manifold.
7. Install EGR pipe to exhaust manifold and EGR valve.,
8. Install EGR pipe to EGR valve, install pipe union. Do not
torque tighten at this stage.
9. Install and torque tighten bolts (x2), EGR pipe to exhaust manifold. Torque tighten pipe union.
10. Connect EGR vacuum hose.
11. Connect throttle body multiplug and harness clip.
12. Connect manifold heating hoses (x2).
13. Connect EGR vacuum pipe to sensor and manifold.
14. Install coolant pipe bracket, install and torque tighten bolts (x2) and nuts (x2).
15. Connect multiplugs to EGR valve, fuel rail pressure
sensor and injectors.
16. Install alternator and injector harness fir tree clips (x3) to coolant pipe bracket.
17. Install heater hose clips (x2) and EGR vacuum lines clips (x2) to bracket.
18. Install harness bracket to engine.
19. Refit harness fir tree clips to cylinder head.
20. Refit engine breather hose.
21. Install VVT solenoid multiplug, position coil and CMP harness (1x edge clip).
22. Install coil cover.
23. Connect breather hose to manifold (quickfit).
24. Connect IAT multiplug.
25. Secure injector harness clips (x2) to LH engine cover.
26. Connect injector multiplugs (x4).
27. Install pipe support bracket, install and tighten nuts (x2
and bolts(x2).
28. Install harness support bracket, install and tighten bolt (x1) and, nut (x1).
29. Install heater hoses (x2) an d throttle body hoses (x2) in
support bracket.
30. Connect breather hoses (x2) to engine cover.
31. Install coil cover.
RH/LH Cylinder Head Gasket - Renew
Removal
1. Re-install front subframe to body, install and tighten bolts (x6), remove support trolley.
2. Install and tighten engine mounting nuts (x2).
3. With assistance, remove engine lifting beam (SPX M553D). 4. Remove SAI pump and bracket assembly (see Workshop
Manual procedure 03.08.DB/03.08.DJ Pump and
Bracket Assembly - Secondary Air Injection - Renew).
5. Disconnect multiplugs (x2) from knock sensors.
6. Disconnect multiplug from camshaft timing sensor.
7. Remove RH/LH exhaust manifold (see Workshop Manual procedure 09.00.CC/09.00.CD Gasket -
Exhaust Manifold - RH/LH - Renew).
8. Remove RH/LH intake camshaft (see Workshop Manual procedure 03.09.AT/03.09.AV Camshaft - Intake - RH/
LH - Renew).
9. Remove RH exhaust camshaft bearing cap retaining bolts (x10) evenly and in stages (see Figure 1).
Figure 1
10. Note their orientation and markings and remove the RH
exhaust camshaft bearing caps.
11. Remove RH exhaust camshaft (see Figure 2).
12. Remove bolts (x2) securing front end of RH cylinder
head to cylinder block.
Repair Operation Time (ROT)
Figure 2
A0309258
A0309260

Evaporative Emissions (03.13)
Engine (03.00)
May 2007 Workshop Manual 3-13-1
Engine (03.00)
Evaporative Emissions (03.13)
Description
The evaporative loss system prevents escape of fuel vapours
into the atmosphere.
Fuel vapour is displaced from the fuel tank during filling.
Vapour is also displaced due to fuel evaporation in higher
temperatures. Displaced fuel vapour is absorbed in the
carbon canister filter located on top of the fuel tank.
During normal engine running, absorbed fuel vapour is
purged from the carbon canisters and mixed with the normal
fuel/air charge in the inlet manifold.
System Operation
Displaced fuel vapour leaves the fuel tank via the normally
open fill level vent valve and the roll over valves. It passes
through the carbon canister where fuel hydrocarbons are
absorbed. Clean air leaves the system via the normally open
canister vent valve. This valve is only closed during
diagnostic pressure testing of the fuel system.
During normal engine ru nning, the single vapour
management valve in the engine bay is periodically opened
allowing fresh air flow into th e open canister vent valve,
through the carbon canister, through the vapour
management valve and into the primary inlet manifold. This
fresh air flow progressively purg es any absorbed fuel vapour
from the carbon canister.

Shock Absorber System (04.03)
Suspension (04.00)
May 2007 Workshop Manual 4-3-5
7. Remove nuts (x3 each side) from damper top mounting and remove engine cross brace support.
8. Remove nuts and bolts each side from damper lower mountings.
9. Remove spring and damper assembly.
10. Position spring compresso r to spring and compress
spring.
11. Hold damper shaft, and remove top mounting retaining nut.
12. Remove top mounting and spring assembly.
13. Remove dust shield from rebound bumper and spring seat flange.
Installation
1. Clean spring , spring seat flange, bumper, dust shield and top mounting .
2. Install spring seat flange, rebound bumper and dust shield onto damper.
3. Install spring and top mounting and install and tighten retaining nut.
4. Remove spring compressor.
5. Install spring and damper assembly and install engine cross brace support.
6. Install top mounting nuts (x3) each side (do not torque tighten).
7. Align damper to lower mounting and install bolts and nuts each side (do not torque tighten).
8. Position upper suspension arm and install bolts and nuts (x2) each side (do not torque tighten).
9. Connect ABS sensor multiplug and install harness clips in upper suspension arm and vertical link.
10. Install road wheel(s).
11. Lower vehicle on ramp.
12. Tighten upper arm nuts an d bolts to correct torque.
13. Torque tighten top mounting nuts (x3) and lower mounting nut and bolt.
14. Align engine cross brace, install Torx bolts (x2) and
tighten Torx bolts (x4) to correct torque.
Rear Spring and Damper Assembly-Pair-
Renew
Removal
1. Open fuel filler lid and remove fuel filler cap.
2. Raise vehicle on ramp.
3. Remove road wheel(s).
4. Remove LH rear wheel arch liner (see Workshop Manual procedure 01.02.HB Wheel Arch Liner - Rear -
RH - Renew).
5. Remove RH wheel arch liner (see Workshop Manual procedure 01.02.JB Wheel Arch Liner - Rear - LH -
Renew).
6. Remove bolt securing fuel filler pipe bracket to shock
absorber mounting bracket.
7. Remove nut securing fuel fille r pipe to body and tie filler
pipe aside (see Fig. 1).
8. Disconnect ABS sensor multiplug (see Fig. 2).
If removed, place the engine
bay cross brace, complete with
mounts, in position.
Caution
Ensure that the brake flex hose is not over stretched.
Caution
Final tightening of suspension components must be
carried out with the suspensi on arms at normal ride
height. Failure to do this wi ll over stress the suspension
bushes when the suspension is deflected to maximum upward travel.
Repair Operation Time (ROT)

Shock Absorber System (04.03)
Suspension (04.00)
May 2007 Workshop Manual 4-3-7
14. Remove spring and damper assembly (see Fig. 8).
15. Remove nuts (x3) each side from damper to mounting plate (see Fig, 9).
Installation
1. Position mounting plate to damper and torque tighten retaining nuts (x3) each side.
2. Install spring and damper assembly and torque tighten upper bolts (x4) each side.
3. Install damper to lower arm each side and torque tighten nuts and bolts.
4. Position fuel filler pipe to body, install and tighten nut.
5. Position fuel filler pipe, install and tighten bolt.
6. Position toe control arm each side, install and torque tighten nuts/bolts.
7. Position handbrake callipers each side, install bolts (x2) each side and tighten bolts to the correct torque.
8. Connect ABS sensor multiplugs each side.
9. Install clips (x2) each side from sensor harness to toe control arms.
10. Install LH wheel arch liner (see Workshop Manual procedure 01.02.HB Wheel Arch Liner - Rear - RH -
Renew). 11. Install RH wheel arch li
ner (see Workshop Manual
procedure 01.02.JB Wheel Arch Liner - Rear - LH -
Renew)
12. Install road wheel(s).
13. Lower vehicle on ramp.
14. Install fuel filler cap and close fuel filler lid.
Rear Spring-Pair-Renew
Removal
1. Open fuel filler lid and remove fuel filler cap.
2. Raise vehicle on ramp.
3. Remove road wheel(s).
4. Remove LH rear wheel arch liner (see Workshop Manual procedure 01.02.HB Wheel Arch Liner - Rear -
RH - Renew).
5. Remove RH wheel arch liner (see Workshop Manual procedure01.02.JB Wheel Arch Liner - Rear - LH -
Renew).
6. Remove bolt securing fuel filler pipe bracket to damper
mounting bracket.
7. Remove nut securing fuel fille r pipe to body and tie filler
pipe aside (see Fig. 1).
Fig. 8
Fig. 9
Repair Operation Time (ROT)

Shock Absorber System (04.03)
Suspension (04.00)
May 2007 Workshop Manual 4-3-9
13. Remove bolts (x4) each side from damper upper mounting (see Fig. 7).
14. Remove spring and damper assembly (see Fig. 8).
15. Remove nuts (x3) each side from damper to mounting plates and remove mounting plates (see Fig. 9).
16. Position spring compresso r to spring and compress
spring.
17. Hold damper shaft and remove top mounting retaining nut. 18. Remove top mounting and spring assembly.
19. Remove spring compressor from spring.
Installation
1. Clean spring and top mounting .
2. Position spring compressor to new spring and compress
spring.
3. Install spring and top mounting and torque tighten retaining nut.
4. Remove spring compressor.
5. Position mounting plate to damper and torque tighten
retaining nuts (x3) each side.
6. Install spring and damper assembly and torque tighten upper bolts (x4) each side.
7. Install damper assembly to lower arm each side and torque tighten nuts and bolts.
8. Position fuel filler pipe to body and install and tighten nut.
9. Position fuel filler pipe and install and tighten bolt.
10. Position toe control arm each side and install and torque tighten nuts and bolts.
11. Position handbrake callipers each side, install bolts (x2) each side and tighten bolts to the correct torque.
12. Connect ABS sensor multiplugs each side.
13. Install clips (x2) each side from sensor harness to toe control arms.
14. Install LH wheel arch li ner. (see Workshop Manual
procedure 01.02.HB Wheel Arch Liner - Rear - RH -
Renew).
15. Install RH wheelwright li ner (see Workshop Manual
procedure 01.02.JB Wheel Arch Liner - Rear - LH -
Renew).
16. Install road wheel(s).
17. Lower vehicle on ramp.
18. Fit fuel filler cap and close fuel filler lid.
Rear Damper-Pair-Renew
Removal
1. Raise vehicle on ramp.
2. Remove road wheel(s).
3. Remove LH rear wheel arch liner (see Workshop Manual procedure 01.02.HB Wheel Arch Liner - Rear -
RH - Renew)
4. Remove RH wheel arch liner (see Workshop Manual procedure 01.02.JB Wheel Arch Liner - Rear - LH -
Renew).
5. Remove bolt securing fuel filler pipe bracket to damper
mounting plate.
6. Remove nut securing fuel fille r pipe to body and tie filler
pipe aside.
7. Disconnect ABS sensor multiplug.
Fig. 7
Fig. 8
Fig. 9
Repair Operation Time (ROT)

Anti-lock Braking System (ABS) (06.09)
Brake system (06.00)
6-9-2 Workshop Manual Issue 4, November 2008
difference between the ideal and actual response within a
tolerance band. This directly influences the forces on the
tires to generate a corrective yaw moment to reduce the side
forces of the tires where appropriate
System Overview
The DSC system embraces capabilities far beyond that of
ABS, or ABS and traction control combined, while relying on
the components of these systems. It also incorporates these
additional sensors for measur ing the vehicle’s motion and
brake system pressure:
Ya w r a t e s e n s o r - located centrally on the transmission
tunnel.
Lateral acceleration sensor - integrated with the yaw rate
sensor.
Steering angle sensor - located on the upper steering
column.
Pressure transducer - located on master cylinder.
The ABS / DSC module supports data exchange with other
vehicle electronic systems via the CAN network; the module
also enables diagnostic interrogation using WDS.
The following components register driver demand and the
ABS / DSC module processes their signals as a basis for
defining an ideal response:
PCM - position of accelerator pedal.
Brake master cylinder pressure transducer - driver’s
braking effort.
Steering angle sensor - position of steering wheel.
There are many supplementary parameters also included in
the processing calculations these include the coefficient of
friction and vehicle speed. The ABS / DSC module monitors
these factors based on signals transmitted by the sensors for:
• Wheel speed
• Lateral acceleration
• Brake pressure
• Yaw rate
Using these parameters, the function of the ABS / DSC
module is to determine the current vehicle status based on
the yaw-rate signal and the slip as estimated by the ABS /
DSC module. It then maintains the vehicle response within
a tolerance of the ‘normal’ behaviour, which is easily
controlled by the driver.
In order to generate the desired yaw behaviour the ABS /
DSC module controls the selected wheels using the ABS
hydraulic system and engine control system. In the event of
engine intervention, the ABS / DSC module calculates the
torque which should be supplied by the engine to the
wheels, and relays this request signal to the PCM which
implements the torque request.
The PCM receives signals from the DSC system via the CAN
bus and reduces engine torque as follows:
• The throttle is positioned to provide the requested engine target torque. • During the transient phase of torque reduction caused by
mechanical and combustion delays, other alternative
torque reduction methods are used to provide a quicker
response.
• The ignition is retarded and / or the fuel is cut-off at the injectors at selected cylinders.
• Ignition and fuelling are reinstated when the engine torque reaches the requested value
Operation Summary
• DSC is switched ‘ON’ when the engine is started
• When the system is operating , the DSC light in the instrument cluster will flash, at the rate of twice a second
• DSC can be switched ‘OFF / ON’ by pressing the DSC switch
• The DSC light in the instru ment cluster will illuminate
continuously when the system is switched ‘Off’.
• ‘DSC OFF’ will be displayed in the message centre right to indicate the system has been switched ‘OFF’
• A malfunction in the traction control system will be indicated to the driver by the following:
• The DSC light in the instru ment cluster will illuminate
continuously
• The message ‘DSC NOT AVAILABLE’ will be displayed in the message centre right
• If vehicle speed control is engaged it will automatically disengage when traction control is operating .
Traction Control
Traction control is a function of DSC, and is operated in
association with DSC. Traction control prevents excessive
wheel-spin at standing starts, or during acceleration. Wheel-
spin is usually caused by ex cessive use of the accelerator
pedal, or slippery, loose or bumpy road surfaces. To prevent
excessive wheel-spin and mainta in vehicle stability such
situations are overcome by the intervention of the traction
control system by:
• Braking the driven-wheel when it starts to slip
• And / or adapting the engine torque to a level corresponding to the traction available on the road
surface.
Functional Description
Traction control uses the ABS electronic and mechanical /
hydraulic hardware with additional valves to control the
braking pressure at the calipe rs. An engine interface also
enables the engine to respond to torque reduction requests
from the traction control. As with ABS, the signals from the
wheel-speed sensors are supplied to the ABS module, where
they are used to calculate the wheel-slip of the individual
wheels. Traction control intervention is initiated if the slip at
one of the wheels is excessive.

Fuel Tank and Lines (10.01)
Fuel (10.00)10-1-4 Workshop Manual May 2007
Jet Pumps
Fuel feed from the fuel pumps is split three ways:
1. Feed to the fuel rails.
2. Feed to the swirl pot jet pump (integral to the FDM).
3. Feed to the externally mounted jet pump (LHS). These pumps ensure that the appropriate pump swirl
pot is maintained with fuel under severe dynamic
conditions.
Filler Neck and Check Valve
Incoming fuel passes through a check valve at the base of the
filler neck. This valve is normally held closed by light spring
pressure. The valve opens under the pressure of incoming
fuel and closes again when fuel flow ceases. The check valve
prevents surging of fuel in the filler neck.
The filler neck also forms part of the on-board refuelling
vapour recovery system. Incoming fuel forms a liquid seal in
the filler neck. Thus any air displaced during fuel tank filling
cannot escape via the filler neck.

-HW3XPS$VV\

&KHFN9DOYH

6HDO)RUPHGLQ)LOOHU1HFN

Fuel Tank and Lines (10.01)
Fuel (10.00)
May 2007 Workshop Manual 10-1-7
Normal Fuel Fill - Air displaced from the fuel tank during
filling can only exit via the fuel level vent valve and roll over
valves and be forced through the carbon canister. Any fuel
vapour in the displaced air is absorbed in the carbon filter
material. No fuel vapour can escape to the atmosphere.
Clean air then exits the carbon canister, via and additional
filter, to atmosphere.
Excessive Fuel Fill - In the event of overfilling of the fuel
tank, the fuel level vent valve will close at normal maximum
fuel level. Finally the roll over vent valve will close,
completely sealing the tank. Any excess pressure in the fuel
tank will ‘blow off’ via the Ov er-pressure vent valve (part of
the roll over vent valves) in the Fuel Level vent valve
assembly.
Safety Precautions
Operations on fuel system resu lt in fuel liquid and vapour
being present in the working environment. This presents a
very serious risk and the following precautions must be
strictly observed:
Specifications
Warning
Operations on refuelling and the fuel system must only
be performed by personnel who have completed training on fuel handling.
Warning
Smoking must not be allowed near the working area. “NO SMOKING” signs must be posted around the
working area.
Warning
Any operation which could involve sparks or naked lights (e.g. battery testing, welding, metal grinding,
etc.) must not be allowed near the working area.
Warning
A CO2 fire extinguisher must be available close at hand.

&DUERQ&DQLVWHU
&DQLVWHU&ORVH 9DOYH
)LOWHU &OHDQ
$LU
Warning
Dry sand must be available close at hand to soak up any accidental fuel spillage.
Warning
If necessary, empty the fuel into an explosion proof container using suitable fireproof fuel handling
equipment.
Warning
The working area must be well ventilated.
Warning
Disconnect the battery before commencing work on the fuel system.
Warning
Depressurise the fuel system before disconnecting any fuel lines.
Pump Pressure
Nominal pump pressure 40 psi (2.7 bar) above inlet
manifold pressure.
Torque Figures
DescriptionNmlb. / ft.
Tank retaining plate bolts 20-25 15-18.5

Fuel Tank and Lines (10.01)
Fuel (10.00)
May 2007 Workshop Manual 10-1-11
Fuel Tank and Canister Assembly-Renew
Removal
1. Disconnect vehicle battery.
2. Remove rear subframe (see Workshop Manual procedure 02.01.CA Subframe Assembly - Rear -
Remove for Access and Refit).
3. Remove fuel filler cap.
4. Remove bolt filler pipe bracket to spring damper
assembly.
5. Remove nut filler neck pipe and hose to body.
6. Release filler neck pipe and hose, collect sealing washer.
7. Remove filler neck pipe and hose assembly from the tank (using filler neck disc onnection tool - 310 - 134)
(see Fig. 2). 8. loosen jubilee clip and disconnect hose from
evaporative emission contro l assembly (see Fig. 3).
9. Disconnect fuel tank harness from main harness (see Fig.
4).
10. Remove nut and release earth lead from stud (see Fig. 5).
Repair Operation Time (ROT)
Warning
Read and follow all fuel hand ling instructions (at the
beginning of the Fuel System section) and the fuel
bowser manufacturers fuel handling documentation
before commencing work on the fuel system. Clean up
spillages immediatel y and dispose of fuel contaminated
materials safely.
Warning
Fuel vapour is explosive. During the following
procedure, fuel tank and fuel lines will be open. Ensure
good ventilation and take all necessary precautions to eliminate fire risk.
Warning
Fire Risk. Before commencing work on the vehicle fuel system, disconnect the earth ( - ve) lead from the
vehicle battery.
Fig. 2
$
Fig. 3
Fig. 4
Fig. 5
$
$%
$&