2010 ASTON MARTIN V8 VANTAGE water pump

Engine Sealing (03.10)
Engine (03.00)3-10-4 Workshop Manual Issue 5, Janauary 2010
20. Put the alternator in position.
21. Install the M8 bolt that attaches the top of the alternator.
22. Install the M10 nut and bolt that attaches the bottom of the alternator.
23. Torque tighten the alternator attachment bolts.
24. Connect the battery cable to the alternator.
25. Install and torque the nut that attaches the battery cable.
26. Install the cover for the cable connection.
27. Connect the electrical connector to the alternator.
28. Apply new engine oil to the seal on a new oil filter.
29. Install the new oil filter.
30. Install the drain tube for the oil separator into the clip in the bracket.
31. Install the drain tube for the oil separator into timing cover.
32. Install the idler pulley for the air conditioning compressor.
33. Install and torque the M10 bolt that attaches the idler pulley.
34. Install the alternator idler pulley.
35. Install and torque the M10 bolt that attaches the idler pulley.
36. Install the auxiliary drive belt tensioner.
37. Install and torque the M10 bolt that attaches the tensioner.
38. Put the water pump pulley in position.
39. Install the three M6 bolts that attach the water pump pulley.
40. Turn the auxiliary drive be lt tensioner until you can
install the drive belt.
41. Torque tighten the three M6 water pump pulley bolts.
42. Clean the coolant manifold and the mating faces on the cylinder heads.
43. Install two new O-ring seals into the coolant manifold.
44. Put the coolant manifold in position.
45. Connect the electrical connector for the temperature sensor.
46. Install the coolant pipe in the manifold.
47. Install and torque tighten the four M6 Torx bolts that attach the coolant manifold to the cylinder heads.
48. Connect the three coolant hoses to the coolant manifold and install the hose clips.
49. Connect the engine breather to the oil separator.
50. Clean the left and right cam covers.
51. Install the inner and outer seals on the left cam cover.
52. Install the left cam cover (Refer to ’Left Side Cam Cover - Remove and Install’, page 3-10-4).
53. Install the inner and outer seals on the right cam cover.
54. Install the right cam cover (Refer to ’Right Side Cam Cover - Remove and Install’, page 3-10-9).
55. Install the front subframe (refer to Workshop Manual procedure 02.01.BA Subframe Assembly - Front -
Remove for Access and Refit). 56. Install the oil tank assembly
(refer to Workshop Manual
procedure 03.02.CA Tank Assembly - Oil Cooler -
Renew).
57. Fill the cooling system (refer to Workshop Manual procedure 03.03.AD Coolant - Drain and Refill).
Left Side Cam Cover - Remove and
Install
Removal
1. Disconnect the battery earth cable.
2. Remove the front crush brace. (Refer to procedure 01.01.LC - Front Crush Brace).
3. Remove the left side front crush bar for the body reinforcement. (Refer to procedure 01.01.AC - Left Side
Front Crush Bar for the Body Reinforcement).
4. Disconnect the breather pi pes from the cam cover and
the oil tank Y-piece.
5. Use applicable caps to seal the open ports.
6. Remove the ignition coil cover.
7. Disconnect the electrical connector from each of the four ignition coils.
8. Disconnect the electrical connector from the Variable
Valve Timing (VVT) solenoid.
9. Release the fir tree clip that attaches the wiring harness for the ignition coils.
10. Move the wiring harness for the ignition coils away.
11. Release the wiring harness for the injectors from the mounts.
12. Cut and remove the three cable ties that attach the rear of the wiring harness for the injectors.
13. Release the purge pipe an d heater pipe from the two
clips on the wiring harness bracket.
14. Remove the two nuts and three screws that attach the front bracket for the wiring harness.
15. Remove the three screws that attach the rear bracket for the wiring harness.
16. Cut and remove the four cable ties that attach the rear
of the wiring harness to the front bracket.
17. Remove the rear bracket for the wiring harness.
18. Remove the front bracket for the wiring harness.
19. Remove the screw that attaches each of the four ignition coils.
20. Remove the four ignition coils.
21. Remove the 14 screws that attach the cam cover to the
engine.
Repair Operation Time (ROT)
ItemCode
Left Side Cam Cover - Remove and
Install 03.10.AS
Note: When you remo ve the cam cover attachment bolts in
the step that follows , record their installed positions in the
cam cover.

Engine Sealing (03.10)
Engine (03.00)
Issue 5, Janauary 2010 Workshop Manual 3-10-11
Removal
1. Remove the left side cam cover (Refer to ’Left Side Cam Cover - Remove and Install’, page 3-10-4).
2. Remove the right side cam cover (Refer to ’Right Side Cam Cover - Remove and Install’, page 3-10-9).
Install
1. Install the left side cam cover (Refer to ’Left Side Cam Cover - Remove and Install’, page 3-10-4).
2. Install the right side cam cover (Refer to ’Right Side Cam Cover - Remove and Install’, page 3-10-9).
Engine Timing Cover-Renew (with Engine
Removed
)
Removal
1. Remove the engine assembly (refer Workshop Manual procedure 03.00.AA Engi ne Assembly - Renew).
2. Position drain container.
3. Remove the drain plug and drain the oil from the sump.
4. Remove the left cam cover (Refer to ’Left Side Cam Cover - Remove and Install’, page 3-10-4).
5. Remove the right cam cover (Refer to ’Right Side Cam Cover - Remove and Install’, page 3-10-9).
6. Release the hose clips and disconnect the two coolant hoses from the coolant manifold.
7. Release the hose clip and di sconnect the hose from the
oil separator.
8. Remove the four Torx bolts that attach the coolant manifold to cylinder heads (refer to Figure 1).
Figure 1
9. Release the coolant mani fold from coolant pipe,
disconnect the temperature sensor multiplug.
10. Remove the coolant manifold.
11. Remove and discard the two O-rings from the coolant manifold. 12. Loosen the three water pump pulley bolts (refer to
Figure 2).
Figure 2
13. Use an applicable socket bar to release the auxiliary
drive belt tensioner.
14. Remove the drive belt.
15. Remove the three bolts and remove the water pump pulley.
16. Remove the bolt that attaches the auxiliary drive belt tensioner.
17. Remove the tensioner (refer to Figure 3).
Figure 3
18. Remove the two bolts that attach the inspection cover to the lower crankcase. Remove the cover.
19. Install tool (303-1185) to hold flywheel. Install and tighten the two bolts .
20. Install the thrust button of tool (303 -1186) into the crankshaft.
21. Put the tool in position in the pulley. Attach the tool with the two bolts. Tighten the centre bolt and remove
the pulley from the crankshaft.
22. Collect the crankshaft pulley, locking ring and the special tool thrust button.
23. Remove the special tool from the pulley.
24. Remove and discard the O-ring seal from pulley.
25. Remove the bolt that attaches the alternator idler pulley.
Repair Operation Time (ROT)
A030368
A030553A
A030553

Engine Sealing (03.10)
Engine (03.00)
Issue 5, Janauary 2010 Workshop Manual 3-10-13
38. Remove the four Torx bolts that attach the PAS pump mounting bracket to the cylinder block. Remove the
bracket (refer to Figure 9).
Figure 9
39. Remove the 27 bolts that attach the timing cover to the engine. Collect the bracet for the oil separator drain
tube. Remove the timing cover.
40. Remove the outer and inner rubber seals from the timing cover (refer to Figure0).
Figure0
41. Remove the front crankshaft oil seal from timing cover.
Installation
1. Clean the timing cover and mating face on engine.
2. Install the inner and outer seals into timing cover.
3. Apply 3mm x 12mm beads of sealant to the eight joints
on the engine.
4. Install the timing cover. Put the oil separator drain tube bracket in position. Install the 27 bolts and torque the
bolts in the specified sequence. 5. Using tool (303-750), instal
l front crankshaft oil seal.
Remove special tool and seal protector.
6. Clean crankshaft pulley and mating face on crankshaft.
7. Lubricate and install new O-ring seal in crankshaft pulley.
8. Install crankshaft pulley, locking ring and new pulley bolt.
9. Torque tighten crankshaft pulley bolt. Remove special tool (303-1185) from crankcase.
10. Install inspection cover to lower crankcase, install and tighten bolts (x2).
11. Install PAS pump mounting bracket, install and torque tighten Torx bolts (x4).
12. Install PAS pump, install and torque tighten bolts (x3).
13. Install alternator mounting bracket, install and torque tighten Torx bolts (x3).
14. Install alternator, install bolt and nut/bolt and torque tighten
15. Connect battery cable, install and torque tighten nut, secure cover. Connect multiplug.
16. Lubricate seal, install new oil filter.
17. Install oil separator drai n tube clip in bracket.
18. Install oil separator drain tube to timing cover.
19. Install A/C compressor idler pulley, torque tighten bolt.
20. Install alternator idler pulley, torque tighten bolt.
21. Install auxiliary drive belt te nsioner, torque tighten bolt.
22. Install water pump pulley, install bolts (x3).
23. Using a suitable socket ba r, release auxiliary drive belt
tensioner, install drive belt.
24. Torque tighten water pump pulley bolts (x3).
25. Clean coolant manifold and mating faces on cylinder heads.
26. Install new O-ring seals (x2) to coolant manifold.
27. Position coolant manifold, connect temperature sensor
multiplug, install coolant pipe in manifold.
28. Install and torque tighten Torx bolts (x4) that attach the coolant manifold to cylinder heads.
29. Connect coolant hoses (x3) to coolant manifold and
secure clips.
30. Connect engine breather to oil separator.
31. Clean left and right cam covers.
32. Install the right cam cover (Refer to ’Right Side Cam Cover - Remove and Install’, page 3-10-9).
33. Install left cam cover (Refer to ’Left Side Cam Cover -
Remove and Install’, page 3-10-4).
34. Install the engine assembly (refer to Workshop Manual procedure 03.00.AA Engine Assembly - Renew).
Caution
Make sure the cranks haft front oil seal mating faces are
clean and dry.
Caution
Do not remove the crankshaft front oil seal protector
until the oil seal is correctly installed.
If you do, the oil seal can be damaged.
A0310243
A0310245
Caution
The bolt thread in the cran kshaft must be cleaned out
before a new crankshaft pulley retaining bolt is installed.
Note: Check the crankshaft pulley and locking ring for damage.

Power Conversion (03.11)
Engine (03.00)3-11-36 Workshop Manual May 2007
4. Ensure that oil seal and special are parallel to rear of
engine.
5. To install oil seal, tighten nuts alternately on tool (303- 1189) until oil seal correctly seated.
6. Remove special tool from crankshaft.
7. Check that the oil seal is located correctly.
8. Install clutch and flywheel assembly (see Workshop Manual procedure 08.00.AA Clutch and Flywheel
Assembly - Renew).
Cylinder Block-Renew
Removal
1. Remove cylinder head gasket - engine set (see Workshop Manual procedure 03.01.HW Gasket -
Cylinder Head - Engine Set - Renew With Engine
Removed).
2. Remove crankshaft assembly.
3. Remove pistons and connecting rod assemblies from cylinder block.
4. Remove Torx screws (x4) securing engine oil cooling
valves to cylinder block.
5. Remove engine oil cooling valves (x4).
6. Remove bolts (x5) securing water pump to cylinder block. Remove water pump, discard gasket.
7. Remove cylinder block valley cover.
Installation
1. Clean cylinder block valley cover and mating face on cylinder block.
2. Install cylinder block valley cover.
3. Clean engine oil cooling valves.
4. Install engine oil cooling valves in cylinder block.
5. Install and torque tighten Torx screws (x4).
6. Clean connecting rods and piston assemblies.
7. Correctly position ring gaps on pistons prior to installation.
8. Remove connecting rod bearing caps.
9. Install bearings in connecting rods and bearing caps.
10. Lubricate cylinder bores, pistons and rings with clean engine oil.
11. Install special tools (303-535) to the connecting rod to prevent damage to crankshaft journal.
12. Install crankshaft assembly.
13. Install new gasket, water pump, install and torque tighten bolts (x5). 14. Install cylinder head gasket - engine set (see Workshop
Manual procedure 03.01.HW Gasket - Cylinder Head -
Engine Set - Renew Wi th Engine Removed).
Crankshaft Damper Pulley Assembly-
Renew (with Engine Removed)
Removal
1. Remove engine assembly (see Workshop Manual
procedure 03.00.AA Engine Assembly - Renew).
2. Release drive belt tensioner, release drive belt from idler pulley (see Figure 1).
Figure 1
3. Remove bolt securing drive belt tensioner to engine timing cover, remove tensioner.
4. Remove drive belt from pulleys.
5. Remove bolts (x2), inspection cover to lower crankcase, remove cover.
6. Install tool (303-1185) to restrain flywheel, install and tighten bolts (x2).
7. Install thrust button of tool (303 -1186) in crankshaft,
position tool in pulley, secure with bolts (x2). Tighten
centre bolt, withdraw pulley from crankshaft.
8. Collect crankshaft pulley, locking ring and special tool thrust button.
9. Remove special tool from pulley.
Caution
Alternate nut tightening to correctly seat the crankshaft rear oil seal.
Repair Operation Time (ROT)
WAR NI NG
DO NOT GET USED ENGINE OIL ON YOUR SKIN.
USED ENGINE OIL CAN BE HARMFUL.
Repair Operation Time (ROT)
ItemCode
Crankshaft Damper Pulley Assembly-
Renew 03.11.DP
A030553

Rear Disc Brakes (06.04)
Brake system (06.00)6-4-2 Workshop Manual May 2007
Maintenance
Rear Brake Disc Set-Renew
Removal
1. Raise vehicle on ramp.
2. Remove road wheel/s
3. Remove pad wear sensors.
4. Remove bleed nipple dust caps.
5. Fit bleed bottle.
6. Loosen bleed nipples, push pistons into Calipers, tighten bleed nipples.
7. Remove bleed bottle.
8. Fit bleed screw dust caps.
9. Remove brake pad retaining pins and anti-rattle springs.
10. Remove Caliper bolts (x4) and tie Caliper aside.
11. Remove handbrake Caliper bolts (x4) and tie Calipers aside.
12. Remove retaining screws (x4) and discs.
Installation
1. Clean hubs.
2. Install discs and retaining screws.
3. Install Calipers and retaining bolts.
4. Install handbrake Ca lipers (bolts x4).
5. Clean components (Caliper s, pins, shims, springs)6. Apply anti-seize compound to pads, pins and shims.
7. Install pads and shims to Caliper.
8. Install retaining pad pins
and springs to Calipers.
9. Install pad wear sensors.
10. Pump brake pedal.
11. Top-up brake fluid.
12. Install road wheel/s
13. Lower vehicle on ramp.
RH/LH Rear Caliper-Renew
Removal
1. Raise vehicle on ramp.
2. Remove road wheel/s
3. Remove pad wear sensor.
4. Ease Caliper pistons to release pads.
5. Remove brake pad retaining pins and anti-rattle spring.
6. Remove pads and shims from Caliper.
7. Remove brake hose (cap and plug open orifices).
8. Remove Caliper bolts (x2) and Caliper.
Repair Operation Time (ROT)
When installing new brake pads, install a new brake pad wear sensor.
WAR NI NG
BEFORE MOVING OFF, PUMP THE FOOT BRAKE 2 OR
3 TIMES TO ENSURE THE FOOT BRAKE WORKS
CORRECTLY. BRAKE CALIPER PISTONS MAY REQUIRE TRAVEL TO CONTACT THE BRAKE PADS AND DISC.
Repair Operation Time (ROT)
ItemCode
Rear Caliper-Renew RH06.04.AB
Rear Caliper-Renew LH06.04.AC
WAR NI NG
AVOID SKIN / EYE CONTACT OR INGESTION OF
BRAKE FLUID. IF SKIN OR EYES ARE SPLASHED WITH BRAKE FLUID, RINSE THE AFFECTED AREA
IMMEDIATELY WITH PLENTY OF WATER AND OBTAIN
MEDICAL ATTENTION. IF BR AKE FLUID IS INGESTED,
OBTAIN IMMEDIATE MEDICAL ATTENTION.
WAR NI NG
BRAKE FLUID IS HYGROSCOPIC. IF KEPT IN OPENED CONTAINERS IT WILL ABSORB WATER VAPOUR. USE ONLY BRAKE FLUID FROM FRESHLY OPENED
CONTAINER.
Caution
Brake fluid must not be allowed to contact the vehicle
paint work. Remove spilt brake fluid from the paint work
by rinsing away with running water.
Place an absorbent cloth around the brake fluid reservoir filler neck to absorb any possible brake fluid spillage.

Rear Disc Brakes (06.04)
Brake system (06.00)
May 2007 Workshop Manual 6-4-3
Installation
1. Clean components (pads, pins, shims, spring)
2. Install new Caliper and secure bolts (x2) (torque).
3. Apply anti-seize compound to pads, pins and shims.
4. Install pads and shims to Caliper.
5. Install retaining pins and spring to Caliper.
6. Install brake pipe (torque).
7. Install pad wear sensor.
8. Remove bleed nipple dust cap.
9. Fit bleed bottle.
10. Top-up brake fluid.
11. Bleed brake Calipe r with assistance.
12. Install bleed nipple dust caps.
13. Remove bleed bottle.
14. Top-up brake fluid.
15. Install road wheel/s
16. Lower vehicle on ramp.
Rear Pad Kit-Renew
Removal
1. Raise vehicle on ramp.
2. Remove road wheel/s
3. Remove pad wear sensors.
4. Remove bleed nipple dust caps.
5. Fit bleed bottle.
6. Loosen bleed nipples, push pistons into Calipers, tighten bleed nipples.
7. Remove bleed bottle.
8. Fit bleed nipple dust caps
9. Remove brake pad retaining pins and anti-rattle springs.
10. Remove pads and shims from Calipers.
Installation
1. Clean components (Caliper s, pins, shims, springs)
2. Apply anti-seize compound to pads, pins and shims.
3. Install pads and shims to Caliper.
4. Install retaining pad pins and springs to Calipers
5. Install pad wear sensors.
6. Pump brake pedal.
7. Top-up brake fluid.
8. Install road wheel/s
9. Lower vehicle on ramp.
WA R N I N G
ALWAYS USE A VACUUM BRUSH OR AQUEOUS
BRAKE CLEANER TO REMOVE BRAKE DUST. NEVER USE COMPRESSED AIR.
When installing new brake pads, install a new brake pad wear sensor.
When bleeding a brake Calipe r, always bleed the inner
bleed screw first, followed by the outer bleed screw, then
bleed the inner bleed screw once again.
WA R N I N G
BEFORE MOVING OFF, PUMP THE FOOT BRAKE 2 OR 3 TIMES TO ENSURE THE FOOT BRAKE WORKS
CORRECTLY. BRAKE CALIPER PISTONS MAY REQUIRE TRAVEL TO CONTACT THE BRAKE PADS AND DISC.
Repair Operation Time (ROT)
WA R N I N G
AVOID SKIN / EYE CONTACT OR INGESTION OF
BRAKE FLUID. IF SKIN OR EYES ARE SPLASHED WITH BRAKE FLUID, RINSE THE AFFECTED AREA
IMMEDIATELY WITH PLENTY OF WATER AND OBTAIN
MEDICAL ATTENTION. IF BRAKE FLUID IS INGESTED, OBTAIN IMMEDIATE MEDICAL ATTENTION.
WA R N I N G
BRAKE FLUID IS HYGROSCOPI C. IF KEPT IN OPENED
CONTAINERS IT WILL ABSORB WATER VAPOUR. USE ONLY BRAKE FLUID FROM FRESHLY OPENED
CONTAINER.
Caution
Brake fluid must not be allo wed to contact the vehicle
paint work. Remove spilt brake fluid from the paint work by rinsing away with running water.
Place an absorbent cloth arou nd the brake fluid reservoir
filler neck to absorb any po ssible brake fluid spillage.
WA R N I N G
ALWAYS USE A VACUUM BRUSH OR AQUEOUS
BRAKE CLEANER TO REMOVE BRAKE DUST. NEVER USE COMPRESSED AIR.
When installing new brake pa ds, install a new brake pad
wear sensor.
WA R N I N G
BEFORE MOVING OFF, PUMP THE FOOT BRAKE 2 OR 3 TIMES TO ENSURE THE FOOT BRAKE WORKS
CORRECTLY. BRAKE CALIPER PISTONS MAY REQUIRE
TRAVEL TO CONTACT THE BRAKE PADS AND DISC.

Air Conditioning (A/C) System (12.03)
Climate Control (12.00)
May 2007 Workshop Manual 12-3-9
Maintenance
Assessment of the A/C system operating efficiency and fault
classification may be achieved by using the facilities on a
Recovery / Recycling / Recharging unit.
Follow the manufacturer's instructions implicitly and observe
all safety considerations.
Connections
Only use hoses with connectors which are dedicated to
HFC 134a charge ports.
Recovery
Read manufacture’s instructions and warnings before
completing any recovery / evacuating and charging
operations.
Warning
Under no circumstances should connections be made with the A/C system in operation or valves open. Should valves be open and a vacuum pump or
refrigerant container attached, an explosion could
occur as a result of high pressure refrigerant being forced back into the vacuum pump or container.
Warning
Handling liquid refrigerant is dangerous. A drop of
refrigerant on the skin can result in localized frostbite. When handling refrigerant, wear gloves and safety
goggles. If refrigerant sp lashes into the eyes,
immediately wash them with clean water and consult a doctor.
Caution
Do not attempt to adapt this unit for R-12 as an A/C
system failure will result. Recovery / Recycle /
Recharging equipment has sp ecial connections to avoid
cross contamination wi th R-12 systems.
The A/C unit’s overfill li mitation mechanism has been
calibrated specifically for use with the 50 lb. (23 Kg)
refillable refrigerant tank.
Run the A/C system for a few minutes before starting the
recovery procedure as this wil l enable more refrigerant to
be recovered. Turn the A/C system off before starting the
procedure.
Ensure the A/C system has pre ssure in it before beginning
the recovery process; if there is no system pressure there is
no refrigerant to recover.
Ensure that the oil drain valve is closed.
Caution
The Recovery / Recycling / Re charging unit relies on a
weighing mechanism to weight the quantity of oil
removed. Ensure that the Recovery / Recycle /
Recharging unit is not disturbed during the recovery procedure.