2010 ASTON MARTIN V8 VANTAGE coolant level

Cooling System (03.03)
Engine (03.00)
Issue 5, Janauary 2010 Workshop Manual 3-3-3
13. Install and tighten pressure cap.
14. Run engine until normal operating temperature is reached.
15. Stop engine, allow to cool down.
16. Re-check coolant level, top-up as necessary.
Thermostat - Renew
Removal
1. Drain Coolant (refer to Workshop Manual procedure 03.03.AD Coolant - Drain and Refill).
2. Release breather valve (bolt x1) and tie aside.
3. Unclip engine harness for access (x4).
4. Remove one end of engine breather hoses for access (x3).
5. Remove breather valve bracket for access (nuts x2 bolt x1).
6. Remove thermostat housing from manifold (bolt x3).
7. Remove thermostat and sealing ring.
Installation
1. Install new thermostat and sealing ring .
2. Install thermostat housing (torque).
3. Install breather valve bracket.
4. Install breather hoses (x3) and clip.
5. Clip engine harness.
6. Install breather valve.
7. Refill coolant (refer to Workshop Manual procedure 03.03.AD Coolant - Drain and Refill).
Wa t e r P u m p - R e n e w
Removal
1. Drain cooling system (refer to Workshop Manual procedure 03.03.AD Coolant - Drain and Refill).
2. Disconnect breather pipe qu ickfits (x2) from air cleaner
duct.
3. Remove throttle body du ct for access. (clips x3). 4. Remove pump pulley bolts (x
3) (refer to Figure 1).
Figure 1
5. Release tensioner and slip belt from idler.
6. Remove pump pulley.
7. Remove pump (bolts x7 ) (refer to Figure 2).
Figure 2
Installation
1. Install pump (bolts x7) (torque), clean mating faces.
2. Fit pulley to pump with bolts.
3. Torque pulley bolts (bolt x3).
4. Release tensioner and slip belt on idler.
5. Install throttle body duct.
6. Connect breather pipe quickf its (x2) to air cleaner duct.
7. Refill cooling system (refer to Workshop Manual procedure 03.03.AD Coolant - Drain and Refill).
Water Pump Pulley - Renew
Removal
1. Battery isolation switch ‘OFF’.
2. Disconnect breather pipe qu ickfits (x2) from air cleaner
duct.
WA R N I N G
DO NOT REMOVE THE PRESSURE CAP WHEN THE
COOLANT IS HOT. ALLOW TIME FOR THE COOLANT /
ENGINE TO COOL. TAKE PARTICULAR CARE TO
AVOID BURNS FROM THE COOLING SYSTEM.
Repair Operation Time (ROT)
Repair Operation Time (ROT)
Repair Operation Time (ROT)
A030350
A030351

Cooling System (03.03)
Engine (03.00)
Issue 5, Janauary 2010 Workshop Manual 3-3-7
5. Raise expansion tank sufficient to disconnect multiplug, release clip, disconnect hose.
6. Remove expansion tank.
Install
1. Position expansion tank, connect multiplug , install hose and secure with clip.
2. Install nut and bolt, tighten to correct torque.
3. Install hoses (x3) on expansion tank, secure with clips (x3).
4. Install LH cross brace, inst all bolts (x4) (torque with
vehicle on level ground).
5. Refill expansion tank to correct level with correct
coolant fluid mixture.
6. Clean up any spilled coolant fluid.
Coolant Recovery Tank Assembly -
Remove and Install
Remove
1. Raise the vehicle and make it safe.
2. On Roadster vehicles, re move the centre undertray.
3. Remove the left side front wheel.
4. Remove the five or six M6 Torx-head screws that attach the rear of the wheelarch liner.
5. Remove the self-tapping screw that attaches the rear of the wheelarch liner into the wheelarch.
6. Turn the steering fully to the left.
7. Move the rear of the wheela rch liner away to get access
to the recovery tank. 8. Release the clip that attaches each of the two hoses (2)
to the recovery tank and release the hoses (refer to
Figure 1).
Figure 1
9. Remove the two M6 screws (3) that attach the recovery tank to the body and remove the recovery tank.
Install
1. Put the recovery tank in position on the body.
2. Install and tighten the two M6 attachment screws (3).
3. Connect the two hoses (2) to the recovery tank.
4. Put the clip back in position on each hose.
5. Put the wheelarch liner back into position.
6. Turn the steering to the centre position.
7. Install the self-tapping screw that attaches the rear of the wheelarch liner into the wheelarch.
8. Install the five or six M6 Torx-head screws that attach the rear of the wheelarch liner.
9. Install the front left roadwheel.
10. On Roadster vehicles, install the centre undertray.
11. Lower the vehicle.
12. Do a check of the coolant level and fill if necessary.
Repair Operation Time (ROT)

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)
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)
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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

Brake Actuation System (06.06)
Brake System (06.00)
May 2007 Workshop Manual 6-6-3
7. Fill reservoir.
8. Bleed Brakes (see Workshop Manual procedure 06.06.AD Pad Kit - Manual Brake and Clutch Pedal -
Renew).
LHD-Brake Master Cylinder Assembly-
Renew
Removal
1. Remove corner cross brace.
2. Move expansion tank aside for access (bolt x1, nut x1, hose clips x2, multiplug x1).
3. Disconnect clutch reservoir feed pipe.
4. Disconnect multiplugs (x2).
5. Disconnect brake pipes from master cylinder (move aside).
6. Remove reservoir holding screw for access to master cylinder retaining nut.
7. Remove master cylinder from booster (nuts x2).
Installation
1. On new master cylinder - Remove reservoir holding screw for access to master cylinder retaining nut.
2. Install master cylinder to booster (nuts x2).
3. Install reservoir holding screw for access to master cylinder retaining nut.
4. Connect brake pipes to master cylinder.
5. Connect clutch reservoir feed pipe. 6. Connect multiplugs (x2).
7. Install expansion tank aside (bolt x1, nut x1, hose clips
x2, multiplug x1).
8. Install corner cross brace (torque) (only fully tighten
when vehicle on level floor).
9. Bleed Brakes (see Workshop Manual procedure 06.06.AD Pad Kit - Manual Brake and Clutch Pedal -
Renew).
10. Top-up coolant.
Clutch Master Cylinder Assembly-Renew
Removal
1. Move drivers seat fully rearward.
2. Remove clevis pin and clip.
3. Remove cylinder securing nuts (x2).
4. Remove fluid (syringe) from brake master cylinder to
below clutch level.
5. Remove corner cross brace.
6. Move expansion tank aside for access (bolt x1, nut x1, hose clips x2, multiplug x1).
7. Disconnect clutch reservoir feed pipe.
8. Disconnect clutch pipe quick fit (pull clip back) and move aside.
9. Remove cylinder assembly.
10. Remove and discard O-ring seal from master cylinder.
11. Split components
12. Remove pipe from cy linder (mark position).
Repair Operation Time (ROT)
Repair Operation Time (ROT)

Brake Actuation System (06.06)
Brake System (06.00)
6-6-4 Workshop Manual May 2007
13. Re-fit components
14. Install pipe to cylinder.
Installation
1. Install new O-ring seal on master cylinder.
2. Install cylinder assembly.
3. Connect pipe to master cylinder (quickfit).
4. Connect clutch reservoir feed pipe.
5. Install expansion tank aside (bolt x1, nut x1, hose clips x2, multiplug x1).
6. Install corner cross brace (torque) (only fully tighten when vehicle on level floor).
7. Install cylinder retaining nuts (x2) (torque).
8. Install clevis pin and clip.
9. Bleed clutch system (see Workshop Manual procedure 08.00.AF - Clutch Hydraulic System - Bleed).
10. Top-up coolant.
RH/LH Front Caliper Hose Assembly-
Renew
Removal
1. Raise vehicle on ramp.
2. Remove road wheel(s).
3. Remove RH/LH front wheel arch liner (see Workshop
Manual procedure 01.02.FB/01.02.GB Wheel Arch
Liner - Front - RH/LH - Renew).
4. Remove bleed nipple dust caps.
5. Position bleed container, connect bleed hose to RHR/ LHR Caliper, open bleed nipples (x1).
6. Position bleed container, connect bleed hose to RHF/ LHF Caliper, open bleed nipples (x1).
7. Depress brake pedal >60 mm and secure with support. 8. Tighten RHR/LHR bleed nipple, disconnect bleed hose,
remove bleed container and fit dust cap.
9. Tighten RHF/LHF bleed nipple, disconnect bleed hose, remove bleed container and fit dust cap.
10. Loosen and disconnect RH/LH front brake tube union from in line connector (see Fig. 1 - RHS shown).
11. Loosen and disconnect RH/LH front brake tube union from hose connection.
12. Release brake tube from clips (x2), remove brake tube.
Installation
1. Install brake tube, connect unions, secure brake tube in clips (x2), torque tighten unions.
2. Install RH/LH front wheel arch liner (see Workshop Manual procedure 01.02.FB/01.02.GB Wheel Arch
Liner - Front - RH/LH - Renew).
3. Remove pedal support.
4. Top-up brake fluid.
5. Bleed brake Caliper with assistance.
6. Remove bleed bottle.
7. Install bleed nipple dust caps.
8. Clean off excess fluid.
9. Top-up brake fluid.
10. Install road wheel(s)).
11. Lower vehicle on ramp.
Repair Operation Time (ROT)
Caution
Always plug pipe ends to prevent ingress of dirt or
moisture into the system.
Fig. 1
A0606125

Power Brake System (06.07)
Brake System (06.00)
May 2007 Workshop Manual 6-7-3
Installation
1. Install booster assembly.
2. Connect brake pipes to master cylinder.
3. Install bolts (x2) clutch pipe bracket.
4. Connect clutch reservoir feed pipe.
5. Connect multiplugs (x4).
6. Install vacuum hose.
7. Install expansion tank asid e (bolt x1, nut x1, hose clips
x2, multiplug x1).
8. Install corner cross brace (torque) (only fully tighten
when vehicle on level floor).
9. Install servo retaining nuts (x4) (torque).
10. Install clevis pin and clip.
11. Bleed Brakes (see Workshop Manual procedure 06.06.AD Pad Kit - Manual Brake and Clutch Pedal -
Renew).
12. Top-up coolant.
Brake Fluid Reservoir-Renew
Removal
1. Remove corner cross brace.
2. Move expansion tank aside for access (bolt x1, nut x1, hose clips x2, multiplug x1).
3. Disconnect clutch reservoir feed pipe.
4. Disconnect multiplugs (x2). 5. Disconnect brake pipes from master cylinder (move
aside).
6. Remove reservoir holding screw for access to master cylinder retaining nut.
7. Remove master cylinder from booster (nuts x2).
8. Remove reservoir from master cylinder.
Installation
1. Fit new seals and install reservoir to master cylinder.
2. Install master cylinder to booster (nuts x2).
3. Install reservoir holding screw for access to master cylinder retaining nut
4. Connect brake pipes to master cylinder.
5. Connect clutch reservoir feed pipe.
6. Connect multiplugs (x2).
7. Install expansion tank aside (bolt x1, nut x1, hose clips x2, multiplug x1).
8. Install corner cross brace (torque) (only fully tighten
when vehicle on level floor).
9. Bleed Brakes (see Workshop Manual procedure 06.07.DD Brake Hydraulic System - Flush/Refill/Bleed).
10. Top-up coolant.
Brake Bleeding - AMDS
Use the AMDS to bleed the brakes if you are bleeding the
brake system after you replaced a major component, for
example: a modulator or a mast er cylinder or when filling
from empty.
If you are bleeding a caliper, you can use a manual brake-
bleed procedure.
1. Connect the AMDS.
Repair Operation Time (ROT)
Repair Operation Time (ROT)