fuel tank removal ASTON MARTIN V8 VANTAGE 2010 Workshop Manual

Handles and Lock Mechanisms (01.14)
Body System (01.00)1-10-4 Workshop Manual May 2007
4. Connect release cable to hand le, position handle, install
and tighten Torx screw.
5. Install and secure hood release cable with fir tree clip.
6. Install hood latch assembly (see Workshop Manual procedure 01.14.BD Latch Assembly - Hood - Renew).
7. Install and secure hood release cable with fir tree clips to under wing bracket and body.
8. Install expansion tank (bolt x1, nut x1, hose clips x2, multiplug x1.
9. Install corner cross brace, install bolts (x4)(torque tighten bolts with vehicle on level floor).
10. Install LH front wheel arch liner (see Workshop Manual
procedure 01.02.FB Wheel Arch Liner - Front - LH -
Renew).
11. Top-up cooling system.
Bonnet Secondary Latch Assembly -
Renew
Removal
1. Open bonnet.
2. Remove Torx screws (x2), securing secondary latch to bonnet (see Figure 1).
3. Remove secondary latch.
4. Remove sleeve from release lever.
Installation
1. Install sleeve on release lever.
2. Install secondary latch, install and torque tighten Torx screws (x2).
3. Close and re-open bonnet, check secondary latch for correct operation.
4. Close hood.
Tailgate Latch and Cable Assembly -
Renew
Removal
1. Remove trim - tailgate lid assembly (see Workshop Manual procedure 01.05.EF Trim - Tailgate Lid Assembly
- Renew).
2. Remove Torx screws (x2) securing latch assembly to
tailgate.
3. Manoeuvre latch from tailgate, disconnect multiplug, remove latch.
4. Release clips (x2), remove bezel from latch.
Installation
1. Install bezel on latch.
2. Install latch in tailgate, align manual release cable.
3. Install and torque tighten Torx screws (x2).
4. Connect multiplug to latch.
5. Install trim - tailgate lid assembly (see Workshop Manual procedure 01.05.EF Trim - Tailgate Lid Assembly -
Renew).
6. Check operation of tailgate opening and closing.
Fuel Filler Actuator Assembly - Renew
(Roadster Only)
Removal
1. Remove luggage compartment lid striker assembly (see Workshop Manual procedure 01.03.GE Striker
Assembly - Trunk Lid - Renew).
2. Remove front luggage compartment carpet (screws x4, trim clip x1).
Repair Operation Time
ItemCode
Bonnet Secondary Latch Assembly-
Renew 01.14.BF
Figure 1
A0114172
Repair Operation Time (ROT)
ItemCode
Tailgate Latch and Cable Assembly-
Renew 01.14.DC
Repair Operation Time (ROT)
ItemCode
Fuel Filler Actuator Assembly-Renew 01.14.FA

Rear Suspension (04.02)
Suspension (04.00)4-2-2 Workshop Manual May 2007
Specifications
Maintenance
RH/LH Rear Hub and Bearing Assembly-
Renew
Removal
1. Raise vehicle on ramp.
2. Remove road wheel(s).
3. Remove RH/LH rear drivesha ft (see Workshop Manual
procedure 05.05.BB/05.05.AB Drive Shaft Assembly -
RH/LH - Renew).
4. Ease caliper pistons to release pads.
5. Remove caliper Allen bolts (x2) release caliper and tie aside.
6. Remove handbrake caliper bolts (x2) and tie caliper aside. 7. Remove brake disc Torx screws (x2), remove disc.
8. Disconnect multiplug fr
om wheel speed sensor.
9. Remove Torx securing wheel speed sensor to vertical link, remove sensor.
10. Remove Allen bolts (x4) se curing hub bearing assembly
in vertical link.
11. Release/remove hub bearing a ssembly from vertical link.
Installation
1. Clean vertical link and mating face on hub bearing
carrier.
2. Install hub bearing assembly. Install and torque tighten Allen bolts (x4).
3. Clean wheel speed sensor.
4. Install wheel speed sensor, install and torque tighten Torx screw.
5. Connect multiplug to wheel sped sensor.
6. Clean disc.
7. Install disc, install and torq ue tighten Torx screws (x2).
8. Install caliper, install and torque tighten Allen bolts (x2).
9. Install handbrake caliper, install and torque tighten
retaining bolts (x2).
10. Install RH/LH driveshaft (see Workshop Manual
procedure 05.05.BB/05.05.AB Drive Shaft Assembly -
RH/LH - Renew).
11. Pump brake pedal.
12. Install road wheel(s).
13. Lower vehicle on ramp.
RH/LH Rear Lower Arm Assembly-Renew
Removal
1. Raise vehicle on ramp.
2. Remove road wheel(s).
3. Remove nut, anti-roll bar li nk to lower suspension arm.
Release link.
4. Remove bolt securing damper to lower suspension arm.
5. Remove bolt and nut/bolt, securing lower suspension arm to subframe.
6. Remove nut/bolt securing lower suspension arm to
vertical link.
7. Release/remove lower suspension arm from subframe and vertical link.
Installation
1. Clean lower suspension arm and mating faces on vertical link, subframe, damper and anti-roll bar link.
2. Install lower suspension ar m to subframe and vertical
link.
Torque Figures
DescriptionNmlb. / ft.
Brake Dust Shield. 9 7
Bearing Assembly to the Vertical
link. 50 37
Halfshaft Nut 300 221.5
Spring and Damper Bracket
Mounting 75-80 55.5-59.5
Spring and Damper Top
Mounting to Bracket 22.5 17
Spring and Damper Lower
Mounting 175 129.5
Track rod Arm to Vertical Link 115 85
Anti-roll Bar Link 110 81.5
Anti-roll Bar Mounting Bolts
Torque bolt 1, then bolt 2, then
bolt 1 again (to allow for rubber
compression) 22.5 17
Ride Height Sensor M8 22.5 17
Torque the following suspensi on fixings with the vehicle
at normal ride height
Vertical Link to the Lower
Suspension Arm. 175 129.5
Vertical Link to the Upper
Suspension Arm. 115 85
Lower Suspension Arm to the
Subframe. 115 85
Upper Suspension Arm to the
Subframe 115 85
Track-Rod Arm to Subframe 115 85
Normal ride height: 2 x 37.5kg in front seats (37.5kg in
each seat) plus a full fuel tank.
Repair Operation Time (ROT)
Repair Operation Time (ROT)
ItemCode
Rear Lower Arm Assembly-Renew RH04.02.AC
Rear Lower Arm Assembly-Renew LH04.02.AD

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
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Fuel Tank and Lines (10.01)
Fuel (10.00)
May 2007 Workshop Manual 10-1-9
11. Remove nut fuel filter clamp to bracket (see Fig. 2).
1. Remove the fuel filter clamp and withdraw the filter.
Installation
1. Position filter in cl amp and install nut (x1).
2. Connect fuel filter hoses (x2).
3. Install fuel tank service cover (nuts x7).
4. Install fuel tank cover with new seal.
5. Install luggage compartment front floor carpet and retainers (x6)
6. install luggage compartment rear floor carpet.
7. Connect battery earth lead.
Fuel Pump and Reservoir Assembly-
Renew
Removal
1. Depressurise 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 release 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.
Fig. 3
Warning
Fire Risk. Do Not connect the vehicle battery and
switch on the ignition until all work on the fuel system
is completed and the area is cleared of fuel
contamination. Remove contaminated material, open fuel containers
and waste fuel. Fully ventilate vehicle and work area to remove all fuel fumes.
Warning
Fire Risk. Do Not start the en gine until the fuel system
integrity is confirmed.
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 immediately and dispose of fuel contaminated materials safely.
Warning
Ensure there is adequate ventilation inside the vehicle
(i.e. place the vehicle in a well ventilated area, with the
windows open).
Warning
Disconnect the battery eart h 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.
$

Fuel Tank and Lines (10.01)
Fuel (10.00)10-1-10 Workshop Manual May 2007
10. Remove recovery unit and fuel tank drainage adaptor.
11. Release the fuel filter hose to pump (x1) quick release
unions (see Fig. 2).
12. Release vent hose from fuel pump assembly (see Fig. 3).
13. Release fuel hose and tank harness from fuel pump bracket clip.
14. Disconnect wiring harness plugs (x2). 15. Install fuel pump removal tool (310-140) (see Fig. 4).
16. Turn the fuel pump anti-clockwise, release and
withdraw pump from mounting.
17. Remove fuel pump.
Installation
1. Position fuel pump in its mounting . Using the service tool, turn clockwise to secure fuel pump.
2. Secure fuel hose and tank harness to bracket
3. Install vent hose to fuel pump.
4. Connect hose to pump assembly.
5. Connect wiring harness multiplugs (x2).
6. Connect fuel filter pipes.
7. Install fuel tank service cover and clamp.
8. Install fuel tank cover with new seal.
9. Install luggage compartment front floor carpet and retainers (x6).
10. Install luggage compartment rear floor carpet.
11. Connect battery earth lead.
Fig. 2
Fig. 3
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Fig. 4
Warning
Fire Risk. Do Not connect the vehicle battery and
switch on the ignition until all work on the fuel system
is completed and the area is cleared of fuel
contamination.
Remove contaminated material, open fuel containers
and waste fuel. Fully ventilat e vehicle and work area to
remove all fuel fumes.
Warning
Fire Risk. Do Not start the en gine until the fuel system
integrity is confirmed.
$

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
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Fig. 3
Fig. 4
Fig. 5
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Fuel Tank and Lines (10.01)
Fuel (10.00)10-1-12 Workshop Manual May 2007
11. Disconnect vapour purge and fuel pipe from the tank
12. Remove bolts (x4) exhaust heatshield to floor.
13. Remove nuts (x5) oil cooler pipes to body.
14. Release exhaust vacuum pipe from clips.
15. Remove vacuum hose clips from studs.
16. Remove vacuum hose clip bolts /stud (x4) tank to body
.
17. With assistance support tank, remove bolts (x14) tank to body and remove fuel tank (see Fig. 6).
18. Disconnect fuel vapour hose quick fit connection to tank (see Fig. 7). 19. Remove nut (x1) fuel tank harness earth (see Fig. 8).
20. Disconnect multiplug (x1) fuel
tank harness (see Fig. 9).
21. Release clips (x5) fuel tank harness and remove harness (see Fig. 10).
Warning
The fuel tank is heavy. Fuel tank removal / replacement is a two person operation.
Fig. 6
Fig. 7
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Fig. 8
Fig. 9
Fig. 10
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Fuel Tank and Lines (10.01)
Fuel (10.00)
May 2007 Workshop Manual 10-1-13
22. Remove cable tie carbon canister to bracket (see Fig. 11).
23. Remove carbon canister from fuel tank (clips 4) (see Fig. 12)
24. Remove tank from support plate.
Installation
1. Position tank to support plate.
2. Install new cable tie behind carbon canister bracket.
3. Align and secure carbon canister to clips (x4).
4. Tighten cable tie around carbon canister.
5. Connect multiplug (x1) fuel tank harness.
6. Install nut (x1) fuel tank harness earth.
7. Secure fuel tank harness (clips x5).
8. Connect fuel vapour hose quick fit connection to tank.
9. With assistance position tank and secure with bolts (x14)
10. Install vacuum hose clip to tank bolts / studs (x4)
11. install vacuum hose clips to studs and secure vacuum
hose.
12. Install nuts (x5) oil cooler to body.
13. Install heatshield. 14. Connect vapour purge and fuel pipe to tank.
15. Position earth lead and secure with nut.
16. Connect fuel tank harness to main harness.
17. Connect evaporative emis
sion control assembly hose
and secure with jubilee clip.
18. install filler neck pipe and hose assembly to fuel tank.
19. Position filler neck pipe, hose assembly and sealing washer to body.
20. Install nut filler neck pipe and hose assembly to body.
21. Install bolt filler pipe brac ket to spring damper assembly.
22. install fuel filler cap
23. Install rear subframe (see Workshop Manual procedure
02.01.CA Subframe Assembly - Rear - Remove for
Access and Refit).
24. Connect vehicle battery.
Fuel Tank and Canister Assembly-
Remove for Access/Refit
Removal
1. Disconnect vehicle battery.
2. Remove rear subframe (see Workshop Manual procedure 02.01.CA Subframe Assembly - Rear -
Remove for Access and Refit).
Fig. 11
Fig. 12
Warning
The fuel tank is heavy. Fuel tank removal / replacement
is a two person operation.
$$
$%
Warning
Fire Risk. Do Not connect the vehicle battery and
switch on the ignition until all work on the fuel system
is completed and the area is cleared of fuel
contamination.
Remove contaminated material, open fuel containers
and waste fuel. Fully ventilate vehicle and work area to remove all fuel fumes.
Warning
Fire Risk. Do Not start the en gine until the fuel system
integrity is confirmed.
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 immediately and dispose of fuel contaminated materials safely.
Warning
Fuel vapour is explosiv e. 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.

Fuel Tank and Lines (10.01)
Fuel (10.00)10-1-14 Workshop Manual May 2007
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 an d disconnect hose from
evaporative emission control 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).
11. Disconnect vapour purge and fuel pipe from the tank
12. Remove bolts (x4) exhaust heatshield to floor.
13. Remove nuts (x5) oil cooler pipes to body.
14. Release exhaust vacuum pipe from clips.
15. Remove vacuum hose clips from studs.
16. Remove vacuum hose clip bolts/stud (x4) tank to body.
Fig. 2
Fig. 3
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Fig. 4
Fig. 5
Warning
The fuel tank is heavy. Fuel tank removal / replacement is a two person operation.
$
$&

Fuel Tank and Lines (10.01)
Fuel (10.00)
May 2007 Workshop Manual 10-1-15
17. With assistance support tank, remove bolts (x14) tank to body and remove fuel tank (see Fig. 6).
Installation
1. With assistance position tank and secure with bolts (x14)
2. Install vacuum hose clip to tank bolts / studs (x4)
3. install vacuum hose clips to studs and secure vacuum hose.
4. Install nuts (x5) oil cooler to body.
5. Install heatshield.
6. Connect vapour purge and fuel pipe to tank.
7. Position earth lead and secure with nut.
8. Connect fuel tank harness to main harness.
9. Connect evaporative emission control assembly hose and secure with jubilee clip.
10. install filler neck pipe and hose assembly to fuel tank.
11. Position filler neck pipe, hose assembly and sealing washer to body.
12. Install nut filler neck pipe and hose assembly to body.
13. Install bolt filler pipe bracket to spring damper assembly.
14. install fuel filler cap
15. Install rear subframe (see Workshop Manual procedure 02.01.CA Subframe Assembly - Rear - Remove for
Access and Refit). 16. Connect vehicle battery.
Fuel Tank Sender Assembly-Renew
Removal
1. Disconnect battery earth lead.
2. Release and remove luggage compartment rear floor
carpet.
3. Remove luggage compartment front floor carpet retainers (x6) and remove carpet.
4. Remove fuel tank cover, clean off the sealant around the aperture.
5. Remove nuts (x7) and release plate clamp and fuel tank service cover.
Fig. 6
Warning
The fuel tank is heavy. Fuel tank removal / replacement
is a two person operation.
Warning
Fire Risk. Do Not connect the vehicle battery and
switch on the ignition until all work on the fuel system
is completed and the area is cleared of fuel
contamination. Remove contaminated material, open fuel containers
and waste fuel. Fully ventilate vehicle and work area to remove all fuel fumes.
$
Warning
Fire Risk. Do Not start the en gine until the fuel system
integrity is confirmed.
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 immediately and dispose of fuel contaminated materials safely.
Warning
Fuel vapour is explosiv e. 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.
Warning
Ensure there is adequate ventilation inside the vehicle
(i.e. place the vehicle in a well ventilated area, with the windows open).
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.