2010 ASTON MARTIN V8 VANTAGE engine

Cooling System (03.03)
Engine (03.00)3-3-12 Workshop Manual Issue 5, Janauary 2010

Fuel Charging System (03.04)
Engine (03.00)
May 2007 Workshop Manual 3-4-1
Engine (03.00)
Fuel Charging System (03.04)
Safety Precautions
Operations on fuel system result 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:
WAR NI NG
OPERATIONS ON REFUELLING AND THE FUEL
SYSTEM MUST ONLY BE PERFORMED BY PERSONNEL WHO HAVE COMPLETED TRAINING ON FUEL HANDLING.
WAR NI NG
SMOKING MUST NOT BE ALLOWED NEAR THE
WORKING AREA. “NO SMOKING” SIGNS MUST BE POSTED AROUND THE WORKING AREA.
WAR NI NG
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.
WAR NI NG
A CO2 FIRE EXTINGUISHER MUST BE AVAILABLE CLOSE AT HAND.
WAR NI NG
DRY SAND MUST BE AVAILABLE CLOSE AT HAND TO SOAK UP ANY ACCIDENTAL FUEL SPILLAGE.
WAR NI NG
IF NECESSARY, EMPTY THE FUEL INTO AN
EXPLOSION PROOF CONTAINER USING SUITABLE
FIREPROOF FUEL HANDLING EQUIPMENT.
WAR NI NG
THE WORKING AREA MUST BE WELL VENTILATED.
WAR NI NG
DISCONNECT THE BATTERY BEFORE COMMENCING WORK ON THE FUEL SYSTEM.
WAR NI NG
DEPRESSURISE THE FUEL SYSTEM BEFORE DISCONNECTING ANY FUEL LINES.

Fuel Charging System (03.04)
Engine (03.00)3-4-2 Workshop Manual May 2007
Maintenance
Fuel Rails - Renew
Removal
1. Depressurise fuel rail (see Workshop Manual procedure
10.01.EK Fuel System - Depressurise).
2. Coolant drain (see Workshop Manual procedure 03.03.AD Coolant - Drain and Refill).
3. Remove cross brace (bolts x4).
Removal RH Side
4. Remove coil cover.
5. Disconnect breather hose (quick fit) move aside.
6. Release harness fir tree clips (x3) from cylinder head and move aside.
7. Remove fuse box bracket fixings (bolt and nut) (allows movement).
8. Remove ECM (see Workshop Manual procedure 03.14.BB Engine Control Module - RH Renew).
9. Remove battery lead (1x nu t and rubber cover) from
fuse box (2x leads).
10. Remove multiplugs (x10) from fusebox.
11. Remove earth terminal (1x nut and rubber cover) from fusebox.
12. Remove fuse box from bracket (bolt x2).
13. Release harness fir tree clips (x3) from engine bracket.
14. Feed harness from inner wing and over engine to gain access to cam cover.
15. Remove purge pipe P-clip (bolt x1) and move pipe
aside.
16. Remove harness bracket from engine (bolts x2, nut x1).
17. Release fuel feed hose from rail (clip x1) and move aside.
18. Disconnect heater hose from pipe (quick fit).
19. Release heater hose (clips x2) and EGR vacuum line (clips x2) from bracket.
20. Release harness from coolant pipe bracket (fir tree x3).
21. Disconnect EGR (x1), fuel rail pressure sensor (x1) and injector multiplugs (x4), move harness aside.
22. Remove coolant pipe bracket (nuts x2 and bolts x2).
23. Disconnect EGR vac pipe from sensor and manifold, move aside.
Removal LH Side
24. Remove corner cross brace.
25. Remove coil cover.
26. Disconnect breather hoses from cam cover (x2) for access.
27. Disconnect purge line from manifold (quickfit) and support clip for access. 28. Disconnect heater hose
from pipe (quick fit).
29. Release heater hose (x2) and throttle body hose (x2) from support bracket.
30. Remove booster hose from manifold and support clip.
31. Remove harness support bracket (bolt x1, nut x2) release harness clips (fir tree x3).
32. Release pipe support bracket (nuts x2, bolts x2) move aside.
33. Disconnect injector multiplugs (x4).
34. Unclip injector harness from cam cover (x2).
35. Disconnect IAT multiplug.
36. Disconnect breather hose from manifold (quickfit).
Removal - Manifold From Vehicle
37. Disconnect manifold heating hoses (x2).
38. Disconnect throttle body multiplug and harness clip.
39. Disconnect breather pipe qu ickfits (x2) from air cleaner
duct.
40. Disconnect air cleaner duct (clip x1).
41. Disconnect EGR vacuum hose.
42. Disconnect EGR pipe union and tie aside.
43. Remove manifold bolts (x 10).
44. Remove bolts (x2) bracket to manifold (rear).
45. Move manifold (2x people) forward, remove bolt for purge line T-clip, remove manifold.
46. Remove gaskets and clean mating faces.
Removal - Manifold Parts
47. Remove Injector to rail clips (x8) (see Figure 1).
Figure 1
48. Remove fuel rail (bolts x4).
Installation
1. Install clips and new O-rings to injectors.
2. Install fuel rail (bolts x4).
Repair Operation Time (ROT)
WAR NI NG
THE INTAKE MANIFOLD IS HEAVY. TO AVOID
PERSONAL INJURY OR DAMAGE TO THE INTAKE MANIFOLD, INTAKE MANIFOLD REMOVAL /
ISTALLATION IS A TWO PERSON OPERATION.
A030113

Fuel Charging System (03.04)
Engine (03.00)
May 2007 Workshop Manual 3-4-3
Installation Manifold to Vehicle
3. Install new gaskets to cylinder block (glue in place).
4. Install manifold (allowing access to install bolt for purge
line P-clip).
5. Install manifold bolts (x10) (torque and tightening sequence).
6. Install bolts (x2) bracket to manifold (rear).
7. Connect EGR pipe union.
8. Connect EGR vacuum hose.
9. Connect air cleaner duct (clip x1).
10. Connect breather pipe quickf its (x2) to air cleaner duct.
11. Connect throttle body multiplug and harness clip.
12. Connect manifold heating hoses (x2).
Installation RH Side
13. Connect EGR vac pipe to sensor and manifold.
14. Install coolant pipe bracket (bolt x2, nut x2).
15. Connect EGR (x1), fuel rail pressure sensor (x1) and
injector multiplugs (x4).
16. Refit harness to coolant pipe bracket (fir tree x3).
17. Connect heater hose to pipe (quick fit).
18. Refit heater hose (clipx2) and EGR vacuum lines (clips x2) to bracket.
19. Install fuel feed pipe.
20. Install purge pipe P-clip.
21. Install harness bracket to engine.
22. Feed harness into inner wing area.
23. Install fusebox to bracket.
24. Install earth lead to fusebox.
25. Install battery lead to fusebox (1x nut and rubber cover).
26. Install multiplugs to fuse box.
27. Install fusebox bracket fixings.
28. Refit harness fir tree clips to cylinder head.
29. Refit engine breather hose.
30. Install VVT solenoid multip lug, position coil and CMP
harness (1x edge clip).
31. Install ECM (see Workshop Manual procedure 03.14.BB XREF: 319 Engine Control Module - RH Renew
32. Install coil cover.
Installation LH Side
33. Connect breather hose to manifold (quickfit).
34. Connect IAT multiplug.
35. Unclip injector harness from cam cover (x2).
36. Connect injector multiplugs (x4).
37. Install pipe support bracket (nuts x2, bolts x2).
38. Install harness support bracket (bolt x1, nut x2) release harness clips (fir tree x3).
39. Connect booster hose to manifold and support clip. 40. Connect heater hose from pipe (quick fit).
41. Install heater hose (x2) and throttle body hose (x2) from
support bracket.
42. Connect purge line to manifold and into support clip.
43. Connect breather hoses (x2) to cam cover.
44. Install coil cover.
45. Install corner cross brace (t orque bolts with vehicle on
level ground).
46. Refill coolant (see Workshop Manual procedure 03.03.AD Coolant - Drain and Refill).
47. Install cross brace (torque bolts with vehicle on level
ground).
Fuel Injection Pressure Sensor - Renew
Removal
1. Depressurise fuel rail (see Workshop Manual procedure 10.01.EK Fuel System - Depressurise).
2. Disconnect vacuum hose.
3. Remove sensor from fuel rail (bolts x2).
4. Disconnect multiplug.
Installation
1. Install sensor to fuel rail (bolts x2) (torque).
2. Connect multiplug.
3. Connect vacuum hose.
Fuel Temperature Sensor - Renew
Removal
1. Depressurise fuel rail (see Workshop Manual procedure 10.01.EK Fuel System - Depressurise).
2. Disconnect vacuum hose.
3. Remove sensor from fuel rail (bolts x2).
4. Disconnect multiplug.
Installation
1. Install sensor to fuel rail (bolts x2) (torque).
2. Connect multiplug.
3. Connect vacuum hose.
WA R N I N G
THE INTAKE MANIFOLD IS HEAVY. TO AVOID
PERSONAL INJURY OR DAMAGE TO THE INTAKE MANIFOLD, INTAKE MANIFOLD REMOVAL /
ISTALLATION IS A TWO PERSON OPERATION.
Installation Not Handed
Repair Operation Time (ROT)
Repair Operation Time (ROT)

Fuel Charging System (03.04)
Engine (03.00)3-4-4 Workshop Manual May 2007
Fuel Injector Engine Set - Renew
Removal
1. Remove LH injectors (see Workshop Manual procedure
03.04.GH Injector - Fuel - LH Bank - Engine Set -
Renew).
2. Remove coils (see Work shop Manual procedure
03.07.HC Coil Assembly - Engine Set - RH - Renew).
3. Disconnect breather hose (quick fit) move aside.
4. Release harness fir tree clips (x3) from cylinder head and move aside.
5. Remove fuse box bracket fixings (bolt and nut) (allows movement).
6. Remove ECM (see Workshop Manual procedure 03.14.BB Engine Control Module - RH Renew).
7. Remove battery lead (1x nu t and rubber cover) from
fuse box (2x leads).
8. Remove multiplugs (x10) from fusebox.
9. Remove earth terminal (1x nut and rubber cover) from
fusebox.
10. Remove fuse box from bracket (bolt x2).
11. Release harness fir tree clips (x3) from engine bracket.
12. Feed harness from inner wing and over engine to gain access to cam cover.
13. Remove purge pipe P-clip (bolt x1) and move pipe
aside.
14. Remove harness bracket from engine (bolts x2, nut x1).
15. Release fuel feed hose from rail (clip x1) and move aside.
16. Disconnect heater hose from pipe (quick fit).
17. Release heater hose (clips x2) and EGR vacuum line (clips x2) from bracket.
18. Release harness from coolant pipe bracket (fir tree x3).
19. Disconnect EGR (x1), fuel rail pressure sensor (x1) and injector multiplugs (x4), move harness aside.
20. Remove coolant pipe bracket (nuts x2 and bolts x2).
21. Disconnect EGR vac pipe from sensor and manifold, move aside. 22. Remove Injector to rail clips (see Figure 1).
Figure 1
23. Remove fuel rail bolts (x2) and lift rail (tie aside) (see
Figure 2).
Figure 2
24. Remove injectors from manifold.
Installation
1. Install clips on to new injectors then fit injectors into manifold.
2. Install rail onto injectors (taking care each injector is aligned correctly and the clip seats properly) and fit bolts
(x2) (torque).
3. Connect EGR vac pipe to sensor and manifold.
4. Install coolant pipe bracket (bolt x2, nut x2).
5. Connect EGR (x1), fuel rail pressure sensor (x1) and
injector multiplugs (x4).
6. Refit harness to coolant pipe bracket (fir tree x3).
7. Connect heater hose to pipe (quick fit).
8. Refit heater hose (clipx2) and EGR vac lines (clips x2) to bracket.
9. Install fuel feed pipe.
10. Install purge pipe P-clip.
11. Install harness bracket to engine.
12. Feed harness into inner wing area.
13. Install fusebox to bracket.
14. Install earth lead to fusebox.
15. Install battery lead to fusebox (1x nut and rubber cover).
16. Install multiplugs to fuse box.
Repair Operation Time (ROT)
A030452
A030113A

Fuel Charging System (03.04)
Engine (03.00)
May 2007 Workshop Manual 3-4-5
17. Install fusebox bracket fixings.
18. Refit harness fir tree clips to cylinder head.
19. Refit engine breather hose.
20. Install VVT solenoid multiplug, position coil and CMP
harness (1x edge clip).
21. Install LH injectors (see Workshop Manual procedure
03.04.GH Injector - Fuel - LH Bank - Each - Renew).
22. Install ECM (see Workshop Manual procedure 03.14.BB Engine Control Module - RH Renew).
1. Install coils (see Workshop Manual procedure 03.07.HC
Coil Assembly - Engine Set - RH - Renew).
Fuel Injector - Each - LH Bank - Renew
Removal
1. Depressurise fuel rail (see Workshop Manual procedure 10.01.EK Fuel System - Depressurise).
2. Remove corner cross brace.
3. Disconnect breather hoses from cam cover (x2) for access.
4. Disconnect purge line from manifold (quickfit) and support clip for access.
5. Disconnect heater hose from pipe (quick fit).
6. Release heater hose (x2) and throttle body hose (x2) from support bracket.
7. Remove booster hose from manifold and support clip.
8. Remove harness support bracket (bolt x1, nut x2) release harness clips (fir tree x3).
9. Release pipe support bracket (nuts x2, bolts x2) move aside.
10. Disconnect IAT multiplug.
11. Disconnect injector multiplugs (x4).
12. Unclip injector harness from cam cover (x2).
13. Disconnect breather hose from manifold (quickfit).
14. Remove Injector to rail clip (for injector to be changed).
15. Remove fuel rail bolts (x2) and lift rail with remaining injectors (tie aside).
16. Remove injector from manifold.
Installation
1. Install new O-rings to remaining injectors (lube O-rings).
2. Install clip to new injector then injector into rail.
3. Install rail (with injectors) to manifold (bolt x2) (torque) (taking care each injector is aligned correctly).
4. Connect breather hose to manifold (quickfit).
5. Connect IAT multiplug.
6. Unclip injector harness from cam cover (x2).
7. Connect injector multiplugs (x4).
8. Install pipe support br acket (nuts x2, bolts x2). 9. Install harness support bracket (bolt x1, nut x2) release
harness clips (fir tree x3).
10. Connect booster hose to manifold and support clip.
11. Connect heater hose from pipe (quick fit).
12. Install heater hose (x2) and throttle body hose (x2) from support bracket.
13. Connect purge line to manifold and into support clip.
14. Connect breather hoses (x2) to cam cover.
15. Install corner cross brace (t orque bolts with vehicle on
level ground).
Fuel Injector - Each - RH Bank - Renew
Removal
1. Depressurise fuel rail (see Workshop Manual procedure 10.01.EK Fuel System - Depressurise).
2. Disconnect breather hose (quick fit) move aside.
3. Release harness fir tree clips (x3) from cylinder head and move aside.
4. Remove fuse box bracket fi xings (bolt and nut) (allows
movement).
5. Remove ECM (see Workshop Manual procedure 03.14.BB Engine Control Module - RH Renew).
6. Remove battery lead (1x nut and rubber cover) from fuse box (2x leads).
7. Remove multiplugs (x10) from fusebox.
8. Remove earth terminal (1x nut and rubber cover) from fusebox.
9. Remove fuse box from bracket (bolt x2).
10. Release harness fir tree clips (x3) from engine bracket.
11. Feed harness from inner wing and over engine to gain access to cam cover.
12. Remove purge pipe P-clip (bolt x1) and move pipe aside.
13. Remove harness bracket from engine (bolts x2, nut x1).
14. Release fuel feed hose from rail (clip x1) and move aside.
15. Disconnect heater hose from pipe (quick fit).
16. Release heater hose (clips x2) and EGR vacuum line
(clips x2) from bracket.
17. Release harness from coolan t pipe bracket (fir tree x3).
18. Disconnect EGR (x1), fuel rail pressure sensor (x1) and injector multiplugs (x4), move harness aside.
19. Remove coolant pipe bracket (nuts x2 and bolts x2).
20. Disconnect EGR vac pipe from sensor and manifold, move aside.
21. Remove Injector to rail clip (for injector to be changed).
22. Remove fuel rail bolts (x2) and lift rail with remaining injectors (tie aside).
23. Remove injector from manifold.
Repair Operation Time (ROT)
Repair Operation Time (ROT)

Fuel Charging System (03.04)
Engine (03.00)3-4-6 Workshop Manual May 2007
Installation
1. Install new O-rings to remaining injectors (lube O-ringP-
clips).
2. Install clip to new injector then injector into rail.
3. Install rail (with injectors) to manifold (bolt x2) (torque)
(taking care each injector is aligned correctly).
4. Connect EGR vac pipe to sensor and manifold.
5. Install coolant pipe bracket (bolt x2, nut x2).
6. Connect EGR (x1), fuel rail pressure sensor (x1) and injector multiplugs (x4).
7. Refit harness to coolant pipe bracket (fir tree x3).
8. Connect heater hose to pipe (quick fit).
9. Refit heater hose (clipx2) and EGR vacuum lines (clips
x2) to bracket.
10. Install fuel feed pipe.
11. Install purge pipe P-clip.
12. Install harness bracket to engine.
13. Feed harness into inner wing area.
14. Install fusebox to bracket.
15. Install earth lead to fusebox.
16. Install battery lead to fusebox (1x nut and rubber cover).
17. Install multiplugs to fuse box.
18. Install fusebox bracket fixings.
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 ECM (see Workshop Manual procedure 03.14.BB Engine Control Module - RH Renew).
Engine Set - Fuel Injector - LH Bank -
Renew
Removal
1. Depressurise fuel rail (see Workshop Manual procedure 10.01.EK Fuel System - Depressurise).
2. Remove corner cross brace.
3. Disconnect breather hoses from cam cover (x2) for access.
4. Disconnect purge line from manifold (quickfit) and
support clip for access.
5. Disconnect heater hose from pipe (quick fit).
6. Release heater hose (x2) and throttle body hose (x2)
from support bracket.
7. Remove booster hose from manifold and support clip.
8. Remove harness support bracket (bolt x1, nut x2) release harness clips (fir tree x3). 9. Release pipe support bracket
(nuts x2, bolts x2) move
aside.
10. Disconnect IAT multiplug.
11. Disconnect injector multiplugs (x4).
12. Unclip injector harness from cam cover (x2).
13. Disconnect breather hose from manifold (quickfit).
14. Remove Injector to rail clips.
15. Remove fuel rail bolts (x2) and lift rail (tie aside).
16. Remove injectors from manifold.
Installation
1. Install clips on to new injectors then fit injectors into manifold.
2. Install rail onto injectors (taking care each injector is aligned correctly and the clip seats properly) and fit bolts
(x2) (torque).
3. Connect breather hose to manifold (quickfit).
4. Connect IAT multiplug.
5. Unclip injector harness from cam cover (x2).
6. Connect injector multiplugs (x4).
7. Install pipe support bracket (nuts x2, bolts x2).
8. Install harness support bracket (bolt x1, nut x2) release harness clips (fir tree x3).
9. Connect booster hose to manifold and support clip.
10. Connect heater hose from pipe (quick fit).
11. Install heater hose (x2) and throttle body hose (x2) from support bracket.
12. Connect purge line to manifold and into support clip.
13. Connect breather hoses (x2) to cam cover.
14. Install corner cross brace (torque bolts with vehicle on level ground).
Engine Set - Fuel Injector - RH Bank -
Renew
Removal
1. Depressurise fuel rail (see Workshop Manual procedure 10.01.EK Fuel System - Depressurise
2. Disconnect breather hose (quick fit) move aside.
3. Release harness fir tree clips (x3) from cylinder head and move aside.
4. Remove fuse box bracket fixings (bolt and nut) (allows movement).
5. Remove ECM (see Workshop Manual procedure 03.14.BB Engine Contro l Module - RH Renew).
6. Remove battery lead (1x nut and rubber cover) from fuse box (2x leads).
7. Remove multiplugs (x10) from fusebox.
Repair Operation Time (ROT)
Repair Operation Time (ROT)
ItemCode
Engine Set-Fuel Injector-RH Bank-
Renew LHD
03.04.GK
Engine Set-Fuel Injector-RH Bank-
Renew RHD
03.04.GP

Fuel Charging System (03.04)
Engine (03.00)
May 2007 Workshop Manual 3-4-7
8. Remove earth terminal (1x nut and rubber cover) from
fusebox.
9. Remove fuse box from bracket (bolt x2).
10. Release harness fir tree clips (x3) from engine bracket.
11. Feed harness from inner wing and over engine to gain access to cam cover.
12. Remove purge pipe P-clip (bolt x1) and move pipe aside.
13. Remove harness bracket from engine (bolts x2, nut x1).
14. Release fuel feed hose from rail (clip x1) and move aside.
15. Disconnect heater hose from pipe (quick fit).
16. Release heater hose (clips x2) and EGR vacuum line (clips x2) from bracket.
17. Release harness from coolant pipe bracket (fir tree x3).
18. Disconnect EGR (x1), fuel ra il pressure sensor (x1) and
injector multiplugs (x 4), move harness aside.
19. Remove coolant pipe bracket (nuts x2 and bolts x2).
20. Disconnect EGR vac pipe from sensor and manifold,
move aside.
21. Remove Injector to rail clips.
22. Remove fuel rail bolts (x2) and lift rail (tie aside).
23. Remove injectors from manifold.
Installation
1. Install clips on to new injectors then fit injectors into manifold.
2. Install rail onto injectors (taking care each injector is aligned correctly and the clip seats properly) and fit bolts
(x2) (torque).
3. Connect EGR vac pipe to sensor and manifold.
4. Install coolant pipe bracket (bolt x2, nut x2).
5. Connect EGR (x1), fuel rail pressure sensor (x1) and
injector multiplugs (x4).
6. Refit harness to coolant pipe bracket (fir tree x3).
7. Connect heater hose to pipe (quick fit).
8. Refit heater hose (clipx2) and EGR vac lines (clips x2) to bracket.
9. Install fuel feed pipe.
10. Install purge pipe P-clip.
11. Install harness bracket to engine.
12. Feed harness into inner wing area.
13. Install fusebox to bracket.
14. Install earth lead to fusebox.
15. Install battery lead to fusebox (1x nut and rubber cover).
16. Install multiplugs to fuse box.
17. Install fusebox bracket fixings.
18. Refit harness fir tree clips to cylinder head.
19. Refit engine breather hose.
20. Install VVT solenoid multip lug, position coil and CMP
harness (1x edge clip).
21. Install ECM (see Workshop Manual procedure 03.14.BB Engine Control Module - RH Renew).