2010 ASTON MARTIN V8 VANTAGE engine

Manual Transmission (07.03)
Transmission (07.00)
Issue 5, January 2010 Workshop Manual 7-3-33
43. Install the tunnel reinforcement plate.
44. Install and torque the eight bolts that attach the tunnel reinforcement plate to the body.
45. Install floor heatshield.
46. Install and tighten the four bolts that attach the floor heat shield to the body.
47. Install the exhaust front mount.
48. Clean the component mating faces.
49. Apply an applicable sealant to the component mating faces.
50. Install the exhaust centre pipe.
51. Install and tighten the four bolts that attach the exhaust centre pipe to the exhaust front mount.
52. Put the clamps into position on the exhaust pipes.
53. Loosely install the four bolts that attach the exhaust centre pipe to the rear silencer.
54. Align the exhaust assembly.
55. Tighten the two clamps that attach the exhaust centre pipe to the catalytic converters.
56. Install the cross brace.
Figure 24
57. Install and torque the four bolts that attach the cross brace to the rear subframe.
Figure 25
58. Remove the strap that attaches the vehicle to the lift.
59. Lower the vehicle until the wheels are approximately 10 mm above the ground.
60. Connect the battery ground cable.
61. Bleed the clutch system.
62. Use AMDS to do an ASM self-tune.
63. Start the engine, select first gear and allow the wheels to turn for 10 seconds.
64. Lift the vehicle.
65. Remove the fill plug for the transaxle oil.
66. Make sure that the transaxle oil is level with the opening for the transaxle oil. Add more oil if necessary.
67. Install and tighten the fill plug for the transaxle oil.
68. Do a check of the ASM fluid level.
69. Install the rear undertray (refer to Workshop Procedure 01.02.PB - Rear Undertray)
Removal
1. Position vehicle on ramp.
2. Remove rear undertray (see Workshop Manual procedure 01.02.PB Undertray - Rear - Renew).
3. Position container to collect transaxle oil.
4. Remove transaxle drain plug and drain oil.
WA R N I N G
THE EXHAUST CENTRE PIPE IS HEAVY. GET THE AID
OF ONE MORE PERSON
TO DO THE STEP THAT FOLLOWS.
Repair Operation Time (ROT)

Clutch Assembly (08.01)
8-1-2 Workshop Manual May 2007
Clutch (08.00)
Clutch Assembly (08.01)
Description
The clutch assembly consists of a balanced flywheel, a clutch
driven plate and a clutch cover.
The clutch is a single plate, diaphragm spring type assembly.
A concentric clutch slave cylinder is mounted around the
first motion shaft in the torque tube bell housing.
The clutch master cylinder is mounted on the engine
bulkhead and is operated directly by the clutch pedal.
A hydraulic connection from the master cylinder feeds
pressurised fluid to the slave cylinder. The slave cylinder has
an extension tube and bleed nipple extending from the left
side of the bell housing for bleeding the system after any
major work.
Specifications
Maintenance
Clutch and Flywheel Assembly-Renew
08.00.AA
Removal
1. Disconnect vehicle battery.
2. Raise vehicle on ramp.
3. Remove torque tube assembly (see Workshop Manual procedure 05.01.CA Torque Tube Remove for Access
and Refit).
4. Remove bolts (x2) from inspection cover to lower crankcase and remove cover. 5. Install special tool SKAM14546 OT to restrain flywheel
and install and tighten bolts (x2) (see Fig. 1).
6. Remove bolts (x6) from clutch cover to flywheel (see Fig.
2).
7. Release clutch cover from dowels, remove cover and collect drive plate.
Clutch Fluid
Castrol/Girling Universal Brake and Clutch fluid.
Clutch Assembly
Clutch and flywheel are separately balanced.
Clutch Plate
Single 267mm driven plate.
Torque Figures
DescriptionNmlb/ft
Flywheel Bolts
Tighten the bolts in sequence. Loosen
the bolts and then torque, in even
stages, in the same sequence. 100 -
120
74-
88.5
Clutch Bolts
Tighten x6 equally-spaced bolts, in-
turn, to pull-down the clutch evenly.
Then torque all bolts in sequence. 65-75 48-55
Starter Motor Bolts 42.5-
57.531.5-
42.5
Repair Operation Time (ROT)
Fig. 1
Fig. 2
Warning
The clutch assembly is heavy. Ensure the clutch
assembly is supported befo re removing final bolts.



Exhaust Overview
Exhaust System (09.00)9-1-2 Workshop Manual Issue 5, January 2010
Exhaust System (09.00)
Exhaust Overview
The exhaust system consists of two four -branch manifolds, two catalytic converte rs, four oxygen sensors and a single
variable flow silencer assembly.
Exhaust gasses flow from the exhaust manifolds, through the catalysts and on to the rear silencer assembly.
• Two engine management oxygen sensors are mounted before the catalysts. • Two catalyst monitor oxygen sensors are mounted in
the catalysts between the primary and secondary
catalyst brick.
09-01-001
Four Branch Manifolds Catalytic Converter Flow Silencer
Oxygen Sensors

Silencer Assembly (09.01)
Exhaust (09.00)
Issue 5, January 2010 Workshop Manual 9-1-3
Exhaust (09.00)
Silencer Assembly (09.01)
Variable Flow Silencer Assembly
The rear silencer assembly has a variable fl ow path controlled by two bypass valves.
The system is intended to enhance top end performance in mo tor sport applications and will not operate in most normal
driving conditions.
By directing exhaust gasses through a modified path at high vehicle speeds, exhaust back pressure is reduced and top end
performance is enhanced.
As engine speed increase from idle, the bypass valve is open until the engine speed is 1500 rpm.
From 1500 rpm to 3000 rpm, the valve is closed
Above 3000 rpm the bypass valves state is load dependent (fully open at higher loads).
Maintenance
LH Catalyst & Pipe Assembly-Renew
Removal
1. Raise vehicle on ramp.
2. Remove rear exhaust silencer (refer to Workshop Manual procedure 09.00.KA Muffler & Bypass Valve
Assembly - Remove for Access & Refit).
3. Disconnect multiplugs (x2), HEGO sensors.
4. Release sensor lead from clip on heatshield.
5. Secure sufficient lengths of string to HEGO sensor multiplugs for assembly purposes.
6. Loosen LH and RH clamp nuts , catalysts to centre pipe.
7. Remove nuts (x3), catalyst to exhaust manifold.
8. With assistance, manoeuvre exhaust centre pipe assembly rearwards to release from catalysts.
9. With assistance, release and support weight of LH catalyst from exhaust manifold.
10. Manoeuvre HEGO sensor le ads and remove cable tie.
Release HEGO sensor leads from behind heat shield.
Secure cable tie. Remove string from HEGO multiplugs.
11. Remove catalyst assembly.
12. Remove and discard gasket. 13. Remove HEGO sensor
s (x2) from catalyst.
Installation
1. Clean catalyst, mating joint faces and HEGO sensors..
2. Install and tighten HEGO sensors (x2) to catalyst.
3. Apply proprietary exhaust se alant around pipe joints.
4. Install new gasket to exhaust manifold flange.
5. With assistance, position cata lyst, secure string (x2) to
HEGO multiplugs, feed sensor leads behind heat shield.
Install catalyst to exhaust manifold.
6. Install and torque tighten nuts (x3), catalyst to exhaust manifold.
7. Align centre pipe asembly to catalyst, torque tighten
clamp nuts.
8. Remove string (x2), conne ct multiplugs (x2), HEGO
sensors.
9. Secure sensor lead in clip on heatshield.
10. Install rear exhaust silencer (refer to Workshop Manual procedure 09.00.KA Muffler & Bypass Valve Assembly -
Remove for Access & Refit).
11. Lower vehicle on ramp.
RH Catalyst & Pipe Assembly-Renew
Repair Operation Time (ROT)
Repair Operation Time (ROT)

Silencer Assembly (09.01)
Exhaust (09.00)9-1-4 Workshop Manual Issue 5, January 2010
Removal
1. Raise vehicle on ramp.
2. Remove rear exhaust silencer (refer to Workshop Manual procedure 09.00.KA Muffler & Bypass Valve
Assembly - Remove for Access & Refit).
3. Disconnect multiplugs (x2), HEGO sensors.
4. Release sensor lead from clip on heatshield.
5. Secure sufficient lengths of string to HEGO sensor multiplugs for assembly purposes.
6. Loosen LH and RH clamp nuts , catalysts to centre pipe.
7. With assistance, manoeuvre exhaust centre pipe assembly rearwards to release from catalysts.
8. Remove nuts (x3), catalyst to exhaust manifold.
9. With assistance, release and support weight of RH catalyst from exhaust manifold.
10. Manoeuvre HEGO sensor leads and remove cable tie. Release HEGO sensor leads from behind heat shield.
Remove string from HEGO multiplugs.
11. Remove catalyst assembly.
12. Remove and discard gasket.
13. Remove HEGO sensors (x2) from catalyst.
Installation
1. Clean catalyst, mating joint faces and HEGO sensors..
2. Install and tighten HEGO sensors (x2) to catalyst.
3. Apply proprietary exhaust sealant around pipe joints.
4. Install new gasket to exhaust manifold flange.
5. With assistance, position catal yst, secure string (x2) to
HEGO multiplugs, feed sensor leads behind heat shield.
Secue cable tie. Install catalyst to exhaust manifold.
6. Install and torque tighten nuts (x3), catalyst to exhaust manifold.
7. Align centre pipe asembly to catalyst, torque tighten
clamp nuts.
8. Remove string (x2), connect multiplugs (x2), HEGO sensors.
9. Secure sensor lead in clip on heatshield.
10. Install rear exhaus t silencer (refer to Workshop Manual
procedure 09.00.KA Muffler & Bypass Valve Assembly -
Remove for Access & Refit).
11. Lower vehicle on ramp.
LH Exhaust Manifold-Renew-Roadster
Only
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).
5. Remove nuts (x8), securing manifold to cylinder head.
6. Remove exhaust manifold, remove and discard gasket.
Installation
1. Clean manifold and mating face on engine. Install new gasket to engine.
2. Install manfold to engine.
3. Install nuts (x8) securing manifold to cylinder head
(torque).
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.
Heated Exhaust Gas Oxygen (HEGO)
Sensor - Remove and Install
Removal
1. Raise the vehicle and make it safe.
2. Release the two electrical connnectors for the Heated Exhaust Gas Oxygen (HEGO) sensor from the bracket.
3. Disconnect the two electrical connnectors from the HEGO sensor.
4. Move the two wiring harnesses for the HEGO sensor away.
5. Remove the two bolts that attach the bracket to the engine.
6. Remove the bracket.
7. Remove the two bolts that attach the heat shield to the torque tube.
8. Move the heat shield away.
Repair Operation Time (ROT)
Repair Operation Time (ROT)
ItemCode
Heated Exhaust Gas Oxygen (HEGO)
Sensor - Remove and Install 09.00.DB
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.

Silencer Assembly (09.01)
Exhaust (09.00)
Issue 5, January 2010 Workshop Manual 9-1-5
9. Release the two wiring harn esses for the HEGO sensor
from the clip on the heat shield.
10. Release the HEGO sensor from the catalytic converter.
11. Install an applicable length of string to the wiring harness and the electrical connector for the HEGO sensor.
12. Use the string to put the wiring harness for the HEGO
sensor behind the heat shield.
13. Release the string from the electrical connector for the HEGO sensor.
14. Remove the HEGO sensor.
15. Clean the component mating faces.
Install
1. Put the HEGO sensor into position.
2. Attach an applicable length of string to the wiring harness for the HEGO sensor.
3. Use the string to put the wiring harness for the HEGO
sensor behind the heat shield.
4. Remove and discard the string.
5. Install the HEGO sensor into the catalytic converter.
6. Tighten the HEGO sensor.
7. Put the heat shield into position.
8. Install and tighten the two bolts that attach the heat shield to the torque tube.
9. Install the two wiring harnesses for the HEGO sensor into the clip on the heat shield.
10. Put the bracket into position.
11. Install and tighten the two bolts that attach the bracket to the engine.
12. Connect the two electrical connnectors to the HEGO
sensor.
13. Install the two electrical connnectors for the HEGO sensor into the bracket.
Silencer and Bypass Valve Assembly-
Remove for Access/Refit-Coupe Only
Removal
1. Raise vehicle on ramp.
2. Remove rear undertray (refer to Workshop Manual procedure 01.02.PB Undertray - Rear - Renew). 3. Remove Allen bolts (x4), bumper diffuser to mounting
brackets. Remove diffuser, collect securing brackets.
4. Disconnect both by-p ass valve vacuum lines.
5. Remove bolts (x4), rear exhaust pipes to silencer. Collect springs from bolts.
6. Remove bolts (x4), securing LH and RH silencer rear hanger brackets to body.
7. Remove bolts (x4), silencer front mountings to subframe.
8. Position suitable lifter to support weight of silencer. With assistance, remove silencer.
9. Remove both rear rubber mountings and hanger brackets from silencer.
Installation
1. Clean muffler and mating faces on rear pipes.
2. Position silencer on lifter. Install silencer, position rear
hangers, install and torque tighten bolts (x4).
3. Position front mountings to subframe, install and torque
tighten bolts (x4).
4. Align silencer to rear pipes, install springs (x4), install and torque tighten bolts (x4).
5. Check silencer to rear pipes for correct alignment and clearances.
6. Connect lines to both by-pass vacuum valves.
7. Position mounting brackets, install rear bumper diffuser. Install and tighten Allen bolts.
8. Install rear undertray (refer to Workshop Manual procedure 01.02.PB Undertray - Rear - Renew).
9. Lower vehicle on ramp.
Silencer and Bypass Valve Assembly-
Remove for Access/Refit-Roadster Only
Removal
1. Raise vehicle on ramp.
CAUTION
Turn the electrical harness for the HEGO sensor when
you remove the sensor in the step that follows. If you do not, the harness can be damaged.
CAUTION
Turn the electrical harness for the HEGO sensor when
you remove the sensor in the step that follows. If you do not, the harness can be damaged.
Repair Operation Time (ROT)
WA R N I N G
THE EXHAUST SYSTEM WILL BE VERY HOT AFTER
OPERATION. LET THE EXHAUST COOL BEFORE YOU DO WORK. IF YOU DO NO T, PESONAL INJURY CAN
OCCUR.
WA R N I N G
GET THE AID OF ONE MORE PERSON WHEN YOU
REMOVE THE REAR EXHAUST SILENCER.
THE SILENCER IS HEAVY .
WA R N I N G
GET THE AID OF ONE MORE PERSON WHEN YOU INSTALL THE REAR EXHAUST SILENCER.
THE SILENCER IS HEAVY .
Ensure correct alignment of exhaust pipes and silencer before tightening of fixing clamps.
Repair Operation Time (ROT)

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.