2010 ASTON MARTIN V8 VANTAGE fuel tank removal

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.
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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.
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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.

Fuel Tank and Lines (10.01)
Fuel (10.00)10-1-16 Workshop Manual May 2007
6. Install the fuel tank drainage adaptor (see Fig. 1).
7. Connect the external pipe to a fuel recovery unit.
Recover the fuel in accordance with the recovery unit
instructions.
8. Remove the recovery unit and fuel tank drainage adaptor.
9. Disconnect fuel tank sender unit multiplug (see Fig. 2).
10. Release fuel tank sender assembly from bracket. 11. Remove fuel tank sender unit (see Fig. 3).
Installation
1. Install sender unit, secure to bracket and connect
multiplug .
2. Install nuts (x7) securing plate clamp and fuel tank
service cover.
3. Install fuel tank cover with new seal.
4. Install luggage compartment front floor carpet and retainers (x6).
5. Install luggage compartment rear floor carpet
.
6. Connect battery earth lead.
Fuel Vapour Pipe Assembly-Renew
Removal
1. Battery isolation switch off.
Fig. 1
Fig. 2
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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 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.
Repair Operation Time (ROT)
ItemCode
Fuel Vapour Pipe Assembly-Renew 10.01.KA
Warning
Read and follow all fuel handling 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 disp ose of fuel contaminated
materials safely.
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Fuel Tank and Lines (10.01)
Fuel (10.00)
May 2007 Workshop Manual 10-1-17
2. Remove RH front wheel arch liner (see Workshop Manual procedure 01.02.GB Wheel Arch Liner - Front -
RH - Renew).
3. Disconnect quick fit connector fuel vapour pipe to tank.
4. Release fuel vapour pipe from fuel line clips (x4).
5. Disconnect quick fit conne ctor fuel vapour pipe
assembly to purge valve T-piece.
6. Remove fuel vapour pipe.
Installation
1. Install fuel vapour pipe and connect to purge valve 'T' piece.
2. Position fuel vapour pi pe in vapour line clips.
3. Connect fuel vapour pipe to fuel tank.
4. Install RH front wheel arch liner (see Workshop Manual procedure 01.02.GB Wheel Arch Liner - Front - RH -
Renew).
5. Battery isolation switch on.
Fuel Supply and Vapour Pipe Assembly-
Renew
Removal
1. Depressurise fuel system (see Workshop Manual procedure 10.01.EK Fuel System - Depressurise).
2. Disconnect vehicle battery. 3. Remove RH front wheel arch liner (see Workshop
Manual procedure 01.02.GB Wheel Arch Liner - Front -
RH - Renew).
4. Position container to collect spillage from fuel supply pipe.
5. Disconnect quick fit connect or fuel supply pipe to tank
6. Release pipe assembly fr om fuel line clips (x3).
7. Disconnect quick fit connect or fuel supply to manifold
supply (fuel rail) and re move pipe assembly.
Installation
1. Connect fuel supply pipe to manifold supply pipe.
2. Position fuel line in fuel line clips (x3).
3. Connect fuel supply pipe to tank.
4. Install RH front wheel arch liner (see Workshop Manual procedure 01.02.GB Wheel Arch Liner - Front - RH -
Renew).
5. Connect vehicle battery.
Manifold Supply Fuel Pipe Assembly-
Renew
Removal
1. Depressurise fuel system (see Workshop Manual procedure 10.01.EK Fuel System - Depressurise).
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. 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 immediatel y and dispose of fuel contaminated
materials safely.
Warning
Fire Risk. Before commencing work on the vehicle fuel system, disconnect the earth ( - ve) lead from the vehicle battery.
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. 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
Fire Risk. Before commencing work on the vehicle fuel system, disconnect the earth ( - ve) lead from the vehicle battery.

Alternator and Regulator System (14.02)
Power Supply (14.00)
May 2007 Workshop Manual 14-2-1
Power Supply (14.00)
Alternator and Regulator System (14.02)
Description
The alternator installed to this vehicle is a Denso, SC1, 120
amp rating, with a 14.4 volt regulator.
The Alternator has an 'Altmon' signal that goes to and from
the PCM via a wire in the 3 way connector.
The ‘Altmon’ signal is monitored by the PCM which adjusts
ignition timing and fuelling if necessary to maintain idle
speed when the alternator is charging.
Specifications
Maintenance
Alternator-Renew
Removal
1. Battery isolation switch ‘OFF’.
2. Disconnect breather pipe qu ickfits (x2) from air cleaner
duct.
3. Remove throttle body du ct for access (clips x3).
4. Release tensioner and slip belt from idler.
5. Move belt off alternator pulley.
6. Reposition oil tank (to release alternator).
7. Remove breather pipe (quick fit).
8. Remove pipes (x2) fr om oil tank, tie aside.
9. Remove bolts (x4) securing tank to body, support tank and move aside to left side of engine bay. 10. Disconnect top hose from engine (clip x1) tie aside
(catch coolant).
11. Raise vehicle on ramp.
12. Remove undertray (see Workshop Manual procedure 01.02.NB Undertray - Front - Renew).
13. Remove bolts (x3) securing oil thermostat to body (allows oil tank more sideways movement).
14. Remove road wheel/s.
15. Remove oil filter and renew (see Workshop Manual procedure 03.02.AB Filter - Oil Canister Renew).
16. Reposition heatsheild to gain access to top bolt.
17. Unclip harness from bracket for access to top bolt and move aside.
18. Remove top securing nut and bolt.
19. Remove nut from bottom fixing and withdraw bolt (will foul on front subframe).
20. Lever alternator forward to release clamping of sliding bushes.
21. Using suitable grips remove bottom/ front sliding bush together with bolt.
22. Position alternator for access, disconnect battery (nut x1) lead and multiplug.
23. Lower ramp.
24. Remove alternator via front of engine (oil tank).
Installation
1. Install alternator.
2. Raise ramp.
3. Connect battery lead and multiplug to alternator.
4. Position alternator to bracket, install top fixing nut and bolt (do not tighten).
5. Install bottom bolt with sliding bush into bracket (through alternator).
6. Install nut to bottom bolt and tighten (torque).
7. Tighten top nut and bolt (torque)
8. Install oil filter and re new (see Workshop Manual
procedure 03.02.AB Filter - Oil Canister Renew).
9. Clip harness to bracket.
10. Reposition heatsheild to original position.
11. Install bolts (x3) securing oil thermostat to body (torque).
12. Install undertray (see Workshop Manual procedure 01.02.NB Undertray - Front - Renew).
13. Install road wheel/s
14. Lower vehicle on ramp.
15. Reposition oil tank.
16. Connect top hose to engine (clip x1).
17. Position tank to body and fit bolts (x4) (torque).
18. Install oil pipes to tank.
19. Connect breather hose.
20. Fit belt to alternator pulley.
Torque Figures
DescriptionNmlb/ft
Alternator mounts 43-52 32-38.5
Repair Operation Time (ROT)