2010 ASTON MARTIN V8 VANTAGE service

Rear Disc Brakes (06.04)
Brake system (06.00)
May 2007 Workshop Manual 6-4-1
Brake system (06.00)
Rear Disc Brakes (06.04)
Description
The rear, four piston, brake caliper is bolted directly to the ve rtical link by two bolts. The caliper is a monobloc assembly.
The steel brake discs are ventilated and grooved. Th ey are secured to the hub by two retaining bolts.
Specifications
06-04-001Caliper BoltRear Caliper
Brake Hose Assy
Brake Pad Kit
Brake Pad Sensor Assy
Rear Brake Disc ShieldGrooved Brake Disc
Oils/Greases
Brake Fluid Castrol Response Super DOT 4 (Not
silicon based brake fluid)
Brake pads
Minimum lining thickness 2.5
Torque Figures
DescriptionNm.lb. / ft.
Brake hose unions 22 16.5
Service brake Caliper to
Vertical Link 20 + 66°-70° 15 + 66°-70°
Handbrake Caliper to
Vertical Link 15 + 90°-94° 11.5 + 90°-94°

Manual Transmission (07.03)
Transmission (07.00)7-3-2 Workshop Manual Issue 5, January 2010
Specifications Maintenance
Transaxle Assembly - Remove for Access
and Install
Removal
1. Disconnect the battery ground cable.
2. Remove the rear undertray (refer to Workshop Manual procedure 01.02.PB - Rear Undertray).
3. Raise the vehicle and install straps to hold it to the lift (refer to Figure 1).
Figure 1
Type
Graziano AM803T transaxle with:
• Integrated Shifter Bellcrack System (Cable Operated)
• Integrated Reverse Switch
• Plate Type Limited Slip Differential
Synchronisers
Triple Cone Syncros on 1st and 2nd, double cone on all
other gears incl. reverse.
Lubrication
Pressure fed system with integrated pump driven by the
input shaft. Filter (filter is serviceable item).
Transaxle Oil
Shell Transaxle 75W/90 (very important that this is the
transaxle type, Do not use Shell Spirax 75W90)
Transaxle Quantity.
Coolant System Quantity. 4 ltr (7 pt / 4.2 US qts)
0.5 ltr (0.9 pt / 0.53 US qts)
Transaxle + Coolant
Quantity 4.5 ltr (7.9 pt / 4.6 US qts)
Gear Ratios
1st 2nd 3rd 4th 5th 6th
3.15:1 1.95:1 1.44:1 1.15:1 0.94:1 0.77:1 (upto VIN
C00525)
0.76:1 (VIN
C00526
Onwards)
Reverse
2.39:1
Differential Locking Ratio
10% Drive, 30% Coast
Torque Figures
DescriptionNm.lb. / ft.
Sump plug 49 36.5
LH Output shaft housing 10 7.5
Halfshaft 70 52
Differential Cover 35 26
Repair Operation Time (ROT)
ItemCode
Transaxle Assembly-Remove for
Access/Refit 07.03.AA
WAR NI NG
WHEN YOU LIFT THE VEHICLE ON A 'TWO POST' LIFT MAKE SURE THAT YOU USE A STRAP TO HOLD THE REAR END OF THE VEHICLE TO THE RAMP. IF YOU
DO NOT, THE VEHICLE CAN FALL OFF THE RAMP AND CAUSE PERSONAL INJURY OR DEATH.
WAR NI NG
THE EXHAUST SYSTEM WILL BE VERY HOT AFTER
OPERATION. LET THE EXHA UST COOL BEFORE YOU
DO WORK. IF YOU DO NO T, PESONAL INJURY CAN
OCCUR.

Manual Control System (07.06)
Transmission (07.00)
May 2007 Workshop Manual 7-6-1
Transmission (07.00)
Manual Control System (07.06)
Maintenance
Gearshift Assembly Mechanism-Renew
Removal
1. Remove panel assembly - console (see Workshop Manual procedure 01.12.DB Panel Assembly Console -
Renew).
2. Using tool (308 - 642), release selector cable ball joints (x2) from gear lever mechanism.
3. Remove screws (x6), securi ng gear lever mechanism to
housing.
4. Remove gearshift assembly mechanism.
5. Remove gear knob, collect gaiter.
Installation
1. Clean gearshift mechanism.
2. Lubricate gearshift mechanism with recommended grease.
3. Install gearshift mechanism, install and tighten screws
(x6).
4. Install selector cables to gearshift mechanism.
5. Install panel assembly - console (see Workshop Manual procedure 01.12.DB Panel Assembly Console - Renew).
6. Install gear lever gaiter, install gear knob.
Transmission Gearshift Cable Assembly-
Renew
Removal
1. Disconnect vehicle battery.
2. Remove panel assembly - console.
3. Using tool 308 - 642, release selector cable ball joint from gear lever mechanism.
4. Remove horseshoe clip secu ring selector to bracket.
5. Raise vehicle on ramp and secure with straps. 6. Remove road wheel(s).
7. Remove rear exhaust muffl
er (see Workshop Manual
procedure 09.00.KA Silencer and Bypass Valve
Assembly - Re move for Access and Refit
8. Remove bolts (x4), subframe cross brace.
9. Loosen clamp nuts (x2), release centre pipe from both catalysts.
10. Remove centre pipe and rear exhaust pipes as an
assembly.
11. Remove bolts (x4), centre heatshield to body, remove heatshield.
12. Remove bolts (x8), shear plate to body, remove shear plate.
13. Remove bolt securing earth lead to transaxle.
14. Mark drive shaft to differential flanges for assembly purposes.
15. Remove and discard Allen bolts (x12), collect plates (x6), drive shaft flanges to transaxle.
16. Release drive shafts from transaxle and position aside.
17. Position drain container to collect oil spillage.
18. Loosen unions and disconnect oil cooler pipes (x2) from
transaxle interconnecting pipes. Plug pipe connections
(x4).
19. Remove drain container.
20. Remove nuts (x2), hydra mounts to subframe mountings.
21. Position hydraulic lifter to support transaxle.
22. Remove and discard bolts (x8 (4 each side), mounting brackets to transaxle. Remove mounting brackets with
hydra mounts.
23. Release reverse lamp switch multiplug from bracket, disconnect multiplug.
24. Lower transaxle sufficiently and use tool (308 - 642) to release selector cable ball joint from selector lever.
25. Remove horse shoe clip securing selector cable to mounting bracket, remove selector cable assembly.
Repair Operation Time (ROT)
Repair Operation Time (ROT)
WA R N I N G
TO AVOID PERSONAL INJURY, I.E. SEVERE BURNS TO
THE SKIN, ALLOW EXHAUST SYSTEM TO COOL DOWN BEFORE REMOVING EXHAUST SYSTEM COMPONENTS.
WA R N I N G
OBSERVE ALL TRANSAXLE OIL MANUFACTURERS SAFETY INSTRUCTIONS WHEN HANDLING
COMPONENTS THAT HAVE BEEN IN CONTACT WITH
TRANSAXLE OIL.
Caution
Plug oil cooler connections to prevent ingress of dirt or moisture into the system.
Caution
Ensure that the service tool No. 0308 - 642 is used to
release selector cable ball joints from selector levers.

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.
$

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.
$

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.
$
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.
$