2010 ASTON MARTIN V8 VANTAGE Workshop Manual

Workshop ManualIssue 6

Workshop Manual

Aston Martin Lagonda Limited
Banbury Road, Gaydon, WARWICK, Warwickshire, England, CV35 0DB
Telephone: (01926) 644700 Fax: (01926) 644733
Aston Martin are constantly seeking to improve the specificat ion, design and production of our vehicles and alterations
take place accordingly. While every effort has been made to ensu re the accuracy of this Manual, it should not be regarded
as an infallible guide to current specifications of any particular vehicle.
All rights reserved. No part of this publication may be reprod uced, stored in a retrieval system or transmitted, in any form,
electronic, mechanical, photocopying, recording or other me ans without prior written permission from Aston Martin
Lagonda Limited.
The manufacturer reserves the right to vary specifications without notice in accordance with its policy of continual product
improvement.
Produced by the Technical Publications Department Aston Martin Lagonda Limited
Issue 6 - March2010

Contents
Issue 5, January 2010 Workshop Manual 0-0-3
V8 Vantage Workshop Manual
Contents
IntroductionWelcome .............................................................. 0-0-6
Safety Precautions ................................................. 0-0-7
Lifting and Jacking ................................................. 0-0-9
Vehicle Recovery ................................................ 0-0-10
Vehicle Identification Number ............................ 0-0-11
Body System (01.00) Body Structure (01.01) .......................................... 1-1-4
Front End System (01.02) ...................................... 1-2-1
Body Closures (01.03) ........................................... 1-3-1
Interior Trim (01.05) ............................................. 1-4-1
Exterior Trim (01.08) ............................................. 1-8-1
Mirrors (01.09) ...................................................... 1-9-1
Seating (01.10).................................................... 1-10-1
Glass, Frame and Mechanism (01.11) .................. 1-11-1
Instrument Panel (IP) (01.12) . .............................. 1-12-1
Handles and Lock Mechanisms (01.14) ............... 1-14-1
Wipers and Washer System (01.16)..................... 1-16-1
Convertible Roof and Roof Opening
Subsystem (01.17)................ ...............................1-17-1
Bumpers (01.19) ................................................. 1-19-1
Restraining Devices (01.20) .... ............................. 1-20-1
Frame and Mounting (02.00) Subframes (02.03) ................................................. 2-1-2
Engine System (03.00) Engine Assembly....................................................3-0-3
Engine Structure (03.01)........................................ 3-1-1
Lubrication System (03.02).................................... 3-2-1
Cooling System (03.03) ......................................... 3-3-1
Fuel Charging System (03.04) ................................ 3-4-1
Accessory Drive System (03.05)............................. 3-5-1
Engine Cranking System (03. 06) ............................ 3-6-1
Valve Train (03.09) ............................................... 3-9-1
Engine Sealing (03.10)......................................... 3-10-1
Power Conversion (03.11)................................... 3-11-1
Evaporative Emissions (03.13) ............................. 3-11-1
Engine Management System (0 3.14).................... 3-14-1
Throttle Control (03.16) ...... ................................ 3-16-1
Foot Operated Control (03.18)............................ 3-18-1
Suspension (04.00) Road Wheel Alignment (04.00) ............................. 4-0-2
Front Suspension (04.01)....................................... 4-1-1
Rear Suspension (04.02)........................................ 4-2-1
Shock Absorber System (04.03) ............................. 4-3-1
Road Wheels and Tyres (04.04) ............................ 4-4-1
Driveline (05.00) Driveshaft (05.01) ................................................. 5-1-2
Halfshafts (05.05) .................................................. 5-2-1 Brake System (06.00)
Front Disc Brake (06.03) ....................................... 6-3-2
Rear Disc Brakes (06.04) ....................................... 6-4-1
Hand Brake (06.05) .............................................. 6-5-1
Brake Actuation System (06.06 ) ............................ 6-6-1
Power Brake System (06.07) ................................. 6-7-1
Anti-lock Braking System (06.09)........................... 6-9-1
Transmission (07.00) Transmission Cooling (07.02) ................................ 7-0-2
Manual Transmission (07.03) ................................ 7-3-1
Automatic Control System (07.05)......................... 7-5-1
Manual Control System (07.06) ............................. 7-6-1
Automatic Shifting Subsytem (07.11) .................. 7-11-1
Clutch (08.00) Clutch Controls (08.02) ......................................... 8-1-2
Exhaust (09.00) Exhaust Overview ................................................. 9-1-2
Silencer Assembly (09.01) ..................................... 9-1-3
Pipes and Supports (09.03) ................................... 9-2-1
Exhaust Protection (09.04) .................................... 9-3-1
Fuel (10.00) Fuel Tank and Lines (10.01) ................................ 10-1-2
Steering (11.00) Steering Gear (11.01) .......................................... 11-1-2
Power Steering (11.02)........................................ 11-2-1
Steering Column (11.04) ..................................... 11-4-1
Steering Column Switches (1 1.05) ....................... 11-5-1
Steering Wheel (11.06) ....................................... 11-6-1
Climate Control (12.00) Body Ventilation system (12.01) .......................... 12-1-2
Heater System (12.02) ........................................ 12-2-1
Air Conditioning (A/C) System (12.03) ................. 12-3-1
Information, Gauge and Warning (13.00) Instrument Cluster (13.01) .................................. 13-1-2
Power Supply (14.00) Battery System (14.01) ........................................ 14-1-2
Alternator and Regulator System (14.02) ............. 14-2-1
Vehicle Entertainment (15.00) Audio System (15.01)................................ ..........15-1-2
Antenna (15.02).................................................. 15-2-1
Vacuum Distribution (16.00) Body Vacuum System (16.01) ............................. 16-1-2
Lighting (17.00) Front Lights (17.01) ............................................. 17-1-2
Interior Lighting (17.02) ...................................... 17-2-1
Rear Lights (17.03) .............................................. 17-3-1
Lighting Mechanisms (17.04). .............................. 17-4-1

Contents
0-0-4 Workshop Manual Issue 5, January 2010
Electric Distribution/Electronic Control (18.00)Wiring and Circuit Protection (18.01) ................. 18-1-2
Vehicle Control System (18.08 ) .......................... 18-2-1
Electronic Features (19.00) Active Anti-Theft System (1 9.01)......................... 19-1-2
Electronic Features Modules (19.08)....................19-2-1
Appendix & Glossary (20.00) Diagnostic Ports.................................................. 20-1-2
Fluids/Capacities................... .............................. 20-1-3
Special Tools - Pictorial Index ............................. 20-1-4
Maintenance Schedules .................................... 20-1-12
Torque Figures ................................................. 20-1-15

Contents
Issue 5, January 2010 Workshop Manual 0-0-5
Introduction
Contents ................................................................. 0-3
Welcome................................................................ 0-0-6 Chapters ................................................................. 0-6Chapter Navigation ................................................ 0-6
Page Numbering ..................................................... 0-6
Systems Classification Coding ................................ 0-6
Special Tools.......................................................... 0-0-6 Location References................................................ 0-6
Warnings, Cautions and Notes .............................. 0-0-6 Repairs and Replacements ..................................... 0-6
Safety Precautions ................................................. 0-0-7 Battery Disconnection ............................................ 0-7
Air Conditioning (A/C) System ................................ 0-7
Chemical Handling and Storage ............................. 0-7
Electrical Equipment .............................................. 0-0-7 Exhaust Fumes ........................................................ 0-7
Fire Precautions ...................................................... 0-7
Tools and Equipment............................................. 0-0-8 Used Engine Oil...................................................... 0-8
Health protection precautions................................ 0-8
Environmental Protection ....................................... 0-8
Lifting and Jacking ................................................. 0-0-9 Safety ...................................................................... 0-9
Jacking Points ........................................................ 0-0-9
Lifting ..................................................................... 0-0-9 Workshop Hoist ..................................................... 0-9
Workshop Jack....................................................... 0-9
Stands .................................................................... 0-9
Vehicle Recovery.................................................. 0-0-10 General ................................................................. 0-10
Transporting ......................................................... 0-10Suspended Towing............................................... 0-10
Adhere to Towing Regulations.............................. 0-10
Towing by Another Vehicle .................................. 0-10
Vehicle Identification Number ............................ 0-0-11
VIN Number Location .......................................... 0-11
Engine Number..................................................... 0-12
Gearbox Number .................................................. 0-12

Welcome
0-0-6 Workshop Manual Issue 5, January 2010
Welcome
This Workshop Manual is part of a suite of technical manuals
provided for V8 Vantage. Other technical manuals include:
• Parts manual
• OBDII Diagnostic manual
• Man hour schedules
Chapters
Each chapter in this workshop manual is associated with a 4
digit number, i.e. Transmission (07.00). Each chapter is then
further broken into sections, i.e. Automatic Transmission
(07.01).
Chapter Navigation
Example 1:
Older workshop manuals would have Steering and
Suspension together in one chapter. The structure now used
places Steering and Suspension into their own chapters.
When required references are made out to other chapters.
Page Numbering
The page numbering system used within this workshop
manual is as follows:
Systems Classification Coding
Alongside the ‘System’ and ‘Sub system’ section titles appear
codes. For example Exhaust ‘ 09.00’ or Power Steering
‘ 11.02 ’. These codes relate to a Corporate Product Systems
Classification (CPSC) and are designed to segregate the parts
for engineering release and organise a variety of engineering
data.
Special Tools
Where special service tools are required to perform an
operation, the tool number is recorded at the point of use
within the procedure. Where the operation of a special
service tool is complicated or not obvious, refer to Appendix
and Glossary for detailed operation procedures. A pictorial
list of special service tools available for this vehicle can also
be found in Appendix and Glossary.
Location References
References to left, right, front or rear of the vehicle or of a
component are referenced from sitting in the drivers seat
facing forward. Any such refe rences to assemblies removed
from the vehicle are to the normal orientation of the
assembly when installed in the vehicle.
The following Warnings, Cautions and Notes are used within
this Owner’s Guide to call your attention to specific types of
information.
Warnings, Cautions and Notes
Warnings
Cautions
Notes
Repairs and Replacements
Where replacement parts are required, it is essential that
only genuine Aston Martin parts are used. Your attention is
drawn to the following points concerning repairs and the
fitting of genuine Aston Martin parts and accessories:
• Safety features embodied in the vehicle may be impaired if other than genuine Aston Martin parts are installed. In
certain territories, legislation prohibits the fitting of parts
which are not produced to the manufacturers
specification
• Adhere to torque wrench settings given in this manual
• Locking devices, where specified, must be installed. If the efficiency of a locking device is impaired during removal,
it must be renewed
• The vehicle warranty may be invalidated by the installation of other than genuine Aston Martin parts
3- 2- 5
System, i.e. Engine system
Subsystem, i.e. Engine lubrication system
Page Number, i.e. Number within subsystem
WAR NI NG
IDENTIFIES PROCEDURES WHICH MUST BE
FOLLOWED PRECISELY TO HELP AVOID THE RISK OF PERSONAL INJURY.
Caution
Provided to indicate procedur es which must be followed
precisely to reduce the possibility of damage to the vehicle.
Provided to indicate procedur es which will help to avoid
difficulties in the oper ation of the vehicle.

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.

Safety Precautions
0-0-8 Workshop Manual Issue 5, January 2010
Tools and Equipment
• Do not leave tools, equipment, spilt oil, etc. around or on the work area.
• Ensure that tools and equipment used are in good condition; do not use damaged or defective tools or
equipment.
• Do not apply heat in an attempt to free stiff nuts or fittings; as well as causing damage to protective coatings, the stray
heat may damage electronic equipment, harnesses and
brake lines.
• Use the recommended service tool where instructed to do so.
Used Engine Oil
Prolonged and repeated contact with mineral oil will result
in the removal of natural fats from the skin, leading to
dryness, irritation and dermatitis. In addition, used engine
oil contains potentially harmful contaminants which may
cause skin cancer. Adequate means of skin protection and
washing facilities should be provided.
Health protection precautions
• Avoid prolonged and repeated contact with oils, particularly used engine oil.
• Wear protective clothing , including impervious gloves where practicable.
• Do not put oily rags in pockets.
• Avoid contaminating clothes with oil.
• Overalls must be cleaned regularly. Discard un-washable clothes and oil impregnated footwear.
• First aid treatment should be obtained immediately for open cuts or wounds.
• Use barrier creams, apply before each work period to help the removal of oil from the skin.
• Wash with soap and water to ensure all oil is removed. Preparations containing lanolin replace the natural skin
oils which have been removed.
• Do not use petrol, kerosene, diesel fuel, gas oil, thinners or solvents for washing skin.
• If skin disorders develop, obtain medical advice.
• Where practicable, degrease components prior to handling .
• Where there is a risk of eye contact, eye protection should
be worn. In addition, an ey e wash facility should be
provided.
Environmental Protection
It is illegal to pour used oil on the ground, down sewers or
drains, or into water courses. The burning of used engine oil
in small space heaters or boilers is not recommended unless
emission control equipment is in stalled; in case of doubt,
contact the Local Authority for ad vice on disposal facilities.