2010 ASTON MARTIN V8 VANTAGE battery

Silencer Assembly (09.01)
Exhaust (09.00)9-1-8 Workshop Manual Issue 5, January 2010
9. Remove nut (x8) securing RH exhaust manifold to cylinder head (refer to Fig. 1).
10. Remove nut (x2) on RH engine mounting.
11. Raise engine by approximately 25mm.
12. Remove RH exhaust manifold from vehicle and discard
gasket.
13. Remove heatshield from manifold (bolts x4)
14. Remove nuts (x8) securing LH exhaust manifold to
cylinder head.
15. Remove exhaust manifold, remove and discard gasket.
Installation
1. Clean LH exhaust manifold and mating face on cylinder head. Install new manifold gasket.
2. Install LH exhaust manifold to cylinder head.
3. Install and torque tighten nuts (x8) securing exhaust manifold to cylinder head.
4. Clean exhaust manifold and mating face on engine. Install new gasket to engine.
5. Install heatshield to manifold (bolts x4)
6. Install RH exhaust mani fold to cylinder head.
7. Install nut (x8) securing manifold to cylinder head
(torque).
8. Lower engine.
9. Install nuts (x2) on engine mounts (torque).
10. Install (nuts x2) EGR pipe from manifold, clean mating face and fit new gasket (torque).
11. Install heatshield deflector, front floor (refer to Workshop Manual procedure 09.04.AA Heatshield -
Front Floor - Renew).
12. Tighten EGR pipe in valve (torque).
13. Install RH front wheel arch liner (refer to Workshop Manual procedure 01.02.GB Wheel Arch Liner - Front -
RH - Renew
14. Install LH wheel arch liner (refer to Workshop Manual procedure 01.02.FB Wheel Arch Liner - Front - LH -
Renew).
15. Lower vehicle on ramp. 16. Connect vehicle battery.
Exhaust System (Excluding Manifold/
Downpipes)-Renew
Removal
1. Raise vehicle on ramp.
2. Remove undertrays - vehicle set (refer to Workshop
Manual procedure 01.02.PD Undertrays - Vehicle Set -
Renew).
3. Remove Allen bolts(x4), bumper diffuser to mounting brackets. Remove diffuser
4. Disconnect both by-pass valve vacuum lines.
5. Remove bolts (x4), securing LH and RH silencer rear
hanger brackets to body. Remove hanger brackets.
6. Remove bolts (x4), rear exha ust pipes to silencer. Collect
springs from bolts
7. Remove bolts (x4), silencer front mountings to subframe. Remove mountings from silencer.
8. Position suitable lifter to support weight of silencer. with assistance, remove silencer.
9. Mark rear stub pipes to si lencer for assembly purposes.
10. Loosen clamps (x2), rear stub pipes to silencer. Remove stub pipes and clamps.
11. Remove bolts (x4), remove rear subframe cross brace.
12. Loosen clamps (x2), release RH and LH rear pipes from centre pipe.
13. Remove rear pipes through subframe.
14. Loosen clamps (x2), centre pipe to LH and RH catalysts.
15. Coupe Only - Release centre pipe from mountings, LH
and RH catalysts, remove centre pipe.
16. Roadster Only - Remove centre exhaust mounting bolts
(x4).
17. Release LH and RH catal ysts, remove centre pipe.
18. Disconnect multiplugs (x4), from each catalyst.
19. Coupe Only - Secure sufficient lengths of string to
HEGO sensor multiplugs for assembly purposes.
Figure 1
A090069
Repair Operation Time (ROT)
ItemCode
Exhaust System (Excluding Manifold/
Downpipes)-Renew 09.00.NB
WAR NI NG
TO AVOID PERSONAL INJURY, I.E. SEVERE BURNS TO
THE SKIN, ALLOW EXHAUS T SYSTEM TO COOL
DOWN BEFORE REMOVING EXHAUST SYSTEM COMPONENTS.
WAR NI NG
GET THE AID OF ONE MORE PERSON WHEN YOU
REMOVE THE REAR EXHAUST SILENCER.
THE SILENCER IS HEAVY .
Attach lengths of string to th e HEGO sensor multiplugs. This
enables routing the HEGO sensor harness behind the exhaust heat shield on assembly.

Pipes and Supports (09.03)
Exhaust System (09.00)9-2-2 Workshop Manual May 2007
5. Install centre pipe to both catalysts and centre mountings. Do not torque clamp nuts at this stage.
6. Install pipe assembly exha ust rear - LH (refer to
Workshop Manual procedure 09.00.JB Pipe Assembly -
Exhaust - Rear - LH - Renew).
7. Install pipe assembly exhaust rear - RH (refer to Workshop Manual procedure 09.00.HB Pipe Assembly
- Exhaust - Rear - RH - Renew).
8. Align and torque tighten exhaust system nuts/bolts.
9. Lower vehicle on ramp.
RH Exhaust Manifold-Renew
Removal
1. Disconnect vehicle battery.
2. Raise vehicle on ramp.
3. Remove RH front wheel arch liner (refer to Workshop Manual procedure 01.02.GB Wheel Arch Liner - Front -
RH - Renew).
4. Loosen EGR pipe in valve.
5. Remove heatshield deflector, front floor (refer to Workshop Manual procedure 09.04.AA Heatshield -
Front Floor - Renew).
6. Remove (nuts x2) EGR pipe from manifold, discard
gasket and tie aside.
7. Remove nut (x8) securing manifold to cylinder head
(refer to Fig. 1).
8. Remove nut (x2) on engine mountings.
9. Raise engine by approximately 25mm. 10. Remove exhaust manifold from vehicle and discard
gasket.
11. Remove heatshield from manifold (bolts x4)
Installation
1. Clean exhaust manifold and mating face on engine. Install new gasket to engine.
2. Install heatshield to manifold (bolts x4)
3. Install manifold to engine.
4. Install nut (x8) securing manifold to cylinder head.
5. Lower engine.
6. Install nuts (x2) on engine mounts.
7. Install (nuts x2) EGR pipe from manifold, clean mating face and fit new gasket (torque).
8. Install heatshield deflector, front floor (refer to Workshop Manual procedure 09.04.AA Heatshield -
Front Floor - Renew).
9. Tighten EGR pipe in valve (torque).
10. Install RH front wheel arch liner (refer to Workshop
Manual procedure 01.02.GB Wheel Arch Liner - Front -
RH - Renew).
11. Lower vehicle on ramp.
12. Connect vehicle battery.
LH Exhaust Manifold-Renew
Removal
1. Disconnect vehicle battery.
2. Raise vehicle on ramp.
3. Remove heatshield deflec tor, front floor (refer to
Workshop Manual procedure 09.04.AA Heatshield -
Front Floor - Renew).
4. Remove LH front wheel arch liner (refer to Workshop Manual procedure 01.02.FB Wheel Arch Liner - Front -
LH - Renew).
Repair Operation Time (ROT)
A090069
Repair Operation Time (ROT)
ItemCode
Exhaust Manifold-Renew LH09.00.CB
WAR NI NG
TO AVOID PERSONAL INJURY, I.E. SEVERE BURNS TO
THE SKIN, ALLOW EXHAUS T SYSTEM TO COOL
DOWN BEFORE REMOVING EXHAUST SYSTEM COMPONENTS.

Pipes and Supports (09.03)
Exhaust System (09.00)
May 2007 Workshop Manual 9-2-3
5. Remove nuts (x8), securing manifold to cinder head
(refer to Fig. 1).
6. Remove exhaust manifold, remove and discard gasket.
Installation
1. Clean manifold and mating face on engine and install
new gasket to engine.
2. Install manifold to engine.
3. Install nuts (x8) securing manifold to cylinder head.
4. Install LH front wheel arch liner (refer to Workshop Manual procedure 01.02.FB Wheel Arch Liner - Front -
LH - Renew).
5. Install heatshield deflector, front floor (refer to Workshop Manual procedure 09.04.AA Heatshield -
Front Floor - Renew).
6. Lower vehicle on ramp.
7. Connect vehicle battery.
RH Exhaust Manifold Gasket-Renew
Removal
1. Remove wheel arch liner (refer to Workshop Manual procedure 01.02.GB Wheel Arch Liner - Front - RH -
Renew).
2. Loosen EGR pipe in valve.
3. Remove heatshield deflector, front floor (refer to Workshop Manual procedure 09.04.AA Heatshield -
Front Floor - Renew).
4. Remove nuts (x2), EGR pipe to manifold, discard gasket
and tie EGR pipe aside. 5. Remove nut (x8) securing ex
haust manifold to cylinder
head.
6. Remove nuts (x2) on engine mountings.
7. Raise engine by approximately 25mm. (care to be taken as inlet manifold can foul).
8. Remove exhaust manifold from vehicle and discard gasket.
Installation
1. Install new gasket to engine, clean mating face on engine.
2. Install manifold to engine.
3. Install nut (x8) securing manifold to cylinder head
(torque).
4. Lower engine.
5. Install nuts (x2) on engine mounts (torque).
6. Install (nuts x2) EGR pipe from manifold, clean mating face and fit new gasket (torque).
7. Install heatshield deflector, front floor (refer to Workshop Manual procedure 09.04.AA Heatshield -
Front Floor - Renew).
8. Tighten EGR pipe in valve (torque).
9. Install wheel arch liner (r efer to Workshop Manual
procedure 01.02.GB Wheel Arch Liner - Front - RH -
Renew).
LH Exhaust Manifold Gasket-Renew
Removal
1. Remove heatshield deflector, front floor (refer to Workshop Manual procedure 09.04.AA Heatshield -
Front Floor - Renew).
2. Remove LH wheel arch liner (refer to Workshop Manual procedure 01.02.FB Wheel Arch Liner - Front - LH -
Renew).
3. Remove nut (x8) securing manifold to cylinder head.
4. Remove manifold from vehicle and discard gasket.
Installation
1. Install new gasket to engine, clean mating face on engine.
2. Install manifold to engine.
3. Install nut (x8) securing manifold to cylinder head
(torque).
4. Install LH wheel arch liner (refer to Workshop Manual procedure 01.02.FB Wheel Arch Liner - Front - LH -
Renew).
Fig. 1
Repair Operation Time (ROT)
302306BA090070
Repair Operation Time (ROT)

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.

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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)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.
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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.
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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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