2010 ASTON MARTIN V8 VANTAGE torque

Pipes and Supports (09.03)
Exhaust System (09.00)
May 2007 Workshop Manual 9-2-1
Exhaust System (09.00)
Pipes and Supports (09.03)
Specifications
Maintenance
RH/LH Catalyst and Pipe Assembly-
Renew
Removal
1. Raise vehicle on ramp.
2. Remove rear exhaust silencer (refer to Workshop Manual procedure 09.00.KA Silencer and Bypass Valve
Assembly - Remove for Access and 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/RH catalyst from exhaust manifold.
10. Manoeuvre HEGO sensor le ads 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. Install new gasket to exhaust manifold flange.
4. With assistance, position cata
lyst, secure string (x2) to
HEGO multiplugs, feed sensor leads behind heat shield.
Install catalyst to exhaust manifold.
5. Install and torque tighten nuts (x3), catalyst to exhaust manifold.
6. Align centre pipe assembly to catalyst, torque tighten clamp nuts.
7. Remove string (x2), conne ct multiplugs (x2), HEGO
sensors.
8. Secure sensor lead in clip on heatshield.
9. Install rear exhaust silencer (refer to Workshop Manual procedure 09.00.KA Silencer and Bypass Valve
Assembly - Remo ve for Access and Refit).
10. Lower vehicle on ramp.
Exhaust Centre Pipe-Renew
Removal
1. Raise vehicle on ramp.
2. Remove pipe assembly exha ust rear - RH (refer to
Workshop Manual procedure 09.00. Pipe Assembly -
Exhaust - Rear - RH - Renew).
3. Remove pipe assembly exha ust rear - LH (refer to
Workshop Manual procedure 09.00.JB Pipe Assembly -
Exhaust - Rear - LH - Renew).
4. Loosen clamp nuts (x2), centre pipe to LH and RH catalysts.
5. Release centre pipe from mountings, LH and RH
catalysts, remove centre pipe.
6. Remove bolts (x3), heatshie ld to centre pipe, remove
heatshield.
7. Remove Torx screws (x4), mounting bracket to centre pipe, remove bracket.
Installation
1. Use a proprietary exhaust seal ant around all pipe joints
prior to installation of exhaust system.
2. Install mounting bracket to centre pipe, install and tighten Torx screws (x4).
3. Install heatshield to centre pipe, install and tighten bolts (x3).
4. Apply exhaust sealant to centre pipe joints.
Torque Figures
DescriptionNmlb. / ft.
Catalyst (nuts / bolts) 25.5-34.5 19-25.5
Catalyst (clamps) 19-22 14.5-16.5
Centre pipe to rear pipe (clamp) 39-51 29-38
Rear Pipe to Silencer (bolt) 28-33 21-24.5
Repair Operation Time (ROT)
Attach lengths of string to th e HEGO sensor multiplugs. This
enables routing the HEGO se nsor harness behind the
exhaust heat shield on assembly.
Repair Operation Time (ROT)

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.

Pipes and Supports (09.03)
Exhaust System (09.00)
May 2007 Workshop Manual 9-2-3
5. Remove nuts (x8), securing manifold to cinder head
(refer to Fig. 1).
6. Remove exhaust manifold, remove and discard gasket.
Installation
1. Clean manifold and mating face on engine and install
new gasket to engine.
2. Install manifold to engine.
3. Install nuts (x8) securing manifold to cylinder head.
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.
RH Exhaust Manifold Gasket-Renew
Removal
1. Remove wheel arch liner (refer to Workshop Manual procedure 01.02.GB Wheel Arch Liner - Front - RH -
Renew).
2. Loosen EGR pipe in valve.
3. Remove heatshield deflector, front floor (refer to Workshop Manual procedure 09.04.AA Heatshield -
Front Floor - Renew).
4. Remove nuts (x2), EGR pipe to manifold, discard gasket
and tie EGR pipe aside. 5. Remove nut (x8) securing ex
haust manifold to cylinder
head.
6. Remove nuts (x2) on engine mountings.
7. Raise engine by approximately 25mm. (care to be taken as inlet manifold can foul).
8. Remove exhaust manifold from vehicle and discard gasket.
Installation
1. Install new gasket to engine, clean mating face on engine.
2. Install manifold to engine.
3. Install nut (x8) securing manifold to cylinder head
(torque).
4. Lower engine.
5. Install nuts (x2) on engine mounts (torque).
6. Install (nuts x2) EGR pipe from manifold, clean mating face and fit new gasket (torque).
7. Install heatshield deflector, front floor (refer to Workshop Manual procedure 09.04.AA Heatshield -
Front Floor - Renew).
8. Tighten EGR pipe in valve (torque).
9. Install wheel arch liner (r efer to Workshop Manual
procedure 01.02.GB Wheel Arch Liner - Front - RH -
Renew).
LH Exhaust Manifold Gasket-Renew
Removal
1. Remove heatshield deflector, front floor (refer to Workshop Manual procedure 09.04.AA Heatshield -
Front Floor - Renew).
2. Remove LH wheel arch liner (refer to Workshop Manual procedure 01.02.FB Wheel Arch Liner - Front - LH -
Renew).
3. Remove nut (x8) securing manifold to cylinder head.
4. Remove manifold from vehicle and discard gasket.
Installation
1. Install new gasket to engine, clean mating face on engine.
2. Install manifold to engine.
3. Install nut (x8) securing manifold to cylinder head
(torque).
4. Install LH wheel arch liner (refer to Workshop Manual procedure 01.02.FB Wheel Arch Liner - Front - LH -
Renew).
Fig. 1
Repair Operation Time (ROT)
302306BA090070
Repair Operation Time (ROT)

Pipes and Supports (09.03)
Exhaust System (09.00)9-2-4 Workshop Manual May 2007
5. Install heatshield deflector, front floor (refer to Workshop Manual procedure 09.04.AA Heatshield -
Front Floor - Renew).
Exhaust Gas Temperature Sensor-Renew
Removal
1. Raise vehicle on ramp.
2. Remove rear exhaust silencer (refer to Workshop Manual procedure 09.00.KA Silencer and Bypass Valve
Assembly - Remove for Access and Refit).
3. Disconnect sensor multiplugs (x2.
4. Release sensor leads from clips (x2) on heatshield.
5. Secure sufficient lengths of string to sensor multiplugs for assembly purposes.
6. Loosen rear 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 sensor leads and remove cable tie. Release sensor leads from behind heat shield. Secure cable tie.
Remove string fr om multiplugs.
11. Remove catalyst assembly.
12. Remove and discard gasket.
13. Remove sensor from catalyst.
Installation
1. Clean catalyst mating joint faces.
2. Install and tighten sensor (x2) (torque).
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
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 assembly to catalyst, torque tighten
clamp nuts.
8. Remove string (x2), connect multiplugs (x2), sensors.
9. Secure sensor leads in clips on heatshield.
10. Install rear exhaust silencer (refer to Workshop Manual procedure 09.00.KA Silencer and Bypass Valve
Assembly - Remove for Access and Refit).
11. Lower vehicle on ramp.
RH/LH Rear Exhaust Pipe Assembly-
Renew
Removal
1. Raise vehicle on ramp.
2. Remove rear undertray.
3. Remove rear silencer assembly (refer to Workshop Manual procedure 09.00.KA Silencer and Bypass Valve
Assembly - Remove for Access and Refit).
4. Remove bolts (x4), cross brace.
5. Loosen clamp nut, release/remove rear intermediate pipe from centre pipe.
6. Remove rear intermediate pipe through subframe.
7. Remove bolts (x4), heat shields (x2).
8. Remove clamp nut, bolt and washers (x2) from rear intermediate pipe.
Installation
1. Clean rear intermediate pipe and mating faces on centre pipe.
2. Install clamp bolt, washers and nut.
3. Position heat shields (x2), install and torque bolts (x4).
4. Apply a proprietary exhaus t sealant to clamp joint.
5. Install rear intermediate pipe to centre pipe.
6. Align rear intermediate pipe to silencer.
7. Install rear silencer assembly (refer to Workshop Manual procedure 09.00.KA Silencer and Bypass Valve
Assembly - Remove for Access and Refit).
8. Torque tighten clamp nut.
9. Install cross brace, install and torque tighten bolts (x4).
10. Install rear undertray.
11. Lower vehicle on ramp.
Repair Operation Time (ROT)
Repair Operation Time (ROT)
ItemCode
Rear Exhaust Pipe Assembly-Renew RH09.00.HB
Rear Exhaust Pipe Assembly-Renew LH09.00.JB
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.

Fuel Tank and Lines (10.01)
Fuel (10.00)
May 2007 Workshop Manual 10-1-7
Normal Fuel Fill - Air displaced from the fuel tank during
filling can only exit via the fuel level vent valve and roll over
valves and be forced through the carbon canister. Any fuel
vapour in the displaced air is absorbed in the carbon filter
material. No fuel vapour can escape to the atmosphere.
Clean air then exits the carbon canister, via and additional
filter, to atmosphere.
Excessive Fuel Fill - In the event of overfilling of the fuel
tank, the fuel level vent valve will close at normal maximum
fuel level. Finally the roll over vent valve will close,
completely sealing the tank. Any excess pressure in the fuel
tank will ‘blow off’ via the Ov er-pressure vent valve (part of
the roll over vent valves) in the Fuel Level vent valve
assembly.
Safety Precautions
Operations on fuel system resu lt in fuel liquid and vapour
being present in the working environment. This presents a
very serious risk and the following precautions must be
strictly observed:
Specifications
Warning
Operations on refuelling and the fuel system must only
be performed by personnel who have completed training on fuel handling.
Warning
Smoking must not be allowed near the working area. “NO SMOKING” signs must be posted around the
working area.
Warning
Any operation which could involve sparks or naked lights (e.g. battery testing, welding, metal grinding,
etc.) must not be allowed near the working area.
Warning
A CO2 fire extinguisher must be available close at hand.

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Warning
Dry sand must be available close at hand to soak up any accidental fuel spillage.
Warning
If necessary, empty the fuel into an explosion proof container using suitable fireproof fuel handling
equipment.
Warning
The working area must be well ventilated.
Warning
Disconnect the battery before commencing work on the fuel system.
Warning
Depressurise the fuel system before disconnecting any fuel lines.
Pump Pressure
Nominal pump pressure 40 psi (2.7 bar) above inlet
manifold pressure.
Torque Figures
DescriptionNmlb. / ft.
Tank retaining plate bolts 20-25 15-18.5

Steering Gear (11.01)
Steering (11.00)11-1-4 Workshop Manual Issue 5, January 2010
Specifications
Excessive steering
efforts required to
turn corners and
during parking
manoeuvres Dirty fluid filter.
Low power steering pump fluid.
Clean/replace reservoir.
Fill as required. Check for system leaks.
Damaged accessory drive belt tensioner. New accessory drive belt tensioner.
Hose or oil cooler external leak. New hose or oil cooler as required.
Hose or cooler line restriction. New hose as required.
Fluid aeration.
Damaged pump. Bleed system.
Replace pump.
Fluid leakage Overfilled system. Correct fluid level.
Component leak. Locate suspect component and repair as required.
Accessory drive belt
squeal Check accessory drive belt for correct tension
or glazing .
New accessory drive belt.
‘Chirp’ noise from
steering pump Loose or worn accessory drive belt. New accessory drive belt.
Power steering
pump noisy Low fluid level. Top up and check for system leaks.
Power steering pump.
Steering hoses fouling body structure. Check for leaks. Repair
as required. New pump.
Ensure hose is secured and routed correctly.
‘Hiss’ noise Fluid flow through steering gear rotary valve -
close to ‘Full Lock’. Normal noise.
‘Whine’ noise Aerated fluid. Bleed system.
Steering wheel
vibration Road wheels out of balance. Check front end alignment.
SymptomPossible CauseAction
Torque Figures
DescriptionNm.lb/ft
Ball Joint (M14 nut) 70 52
Track-Rod (lock nut) 70 52
Steering Rack to Subframe (M12) 115 85
Steering Rack Pipe Attachment Plate 9-12 7-9
Intermediate Shaft Pinch Bolt 21-29 15.5-21.5

Power Steering (11.02)
Steering (11.00)11-2-2 Workshop Manual Issue 5, January 2010
Maintenance
Power Steering System - Bleed
Procedure
1. Do a check of the fluid level in the PAS fluid reservoir. Add fluid if necessary.
2. Start the engine and let it idle for 20 seconds.
3. Operate the steering fully to the left and then the right through three cycles.
4. Stop the engine.
5. Wait for five minutes then do a check of the fluid level in the PAS fluid reservoir again.
6. Add fluid if necessary.
7. Install the PAS fluid reservoir cap.
Power Steering Pump-Renew
Removal
1. Remove A/C compressor (see Workshop Manual procedure 03.05.BE Compre ssor - Air Conditioning -
Renew).
2. Coolant drain (see Workshop Manual procedure 03.03.AD Coolant - Drain & Refill).
3. Remove PAS fluid from reservoir.
4. Disconnect HP union from PAS pump pipe.
5. Remove bolt P-clip suction hose to body.
6. Remove bolt (x1) HP pump pipe to engine.
7. Remove bolts (x3) PAS pump to engine.
8. Disconnect bottom hose and move aside.
9. Unclip (x1) harness from cylinder head for access.
10. Manouvre pump forward and up.
11. Disconnect suction hose (cut off clip) and remove pump.
12. Remove HP union pipe from pump (mark position on
pump).
Installation
1. Install HP union pipe to pump (align correctly), fit new O-ring.
2. Install pump to vehicle connect suction pipe to PAS pump, align timing marks and fit new clip.
3. Manouvre pump into position.
4. Install bolts (x3) PAS pump to engine (torque).
5. Install bolt (x1) HP pump pipe to engine (torque).
6. Connect bottom hose.
7. Clip (x1) harness from cylinder head for access. 8. Install bolt P-clip suction hose to body (torque).
9. Connect HP union to PAS pump pipe, replace O-ring
(torque).
10. Coolant refill (see Workshop Manual procedure 03.03.AD Coolant - Drain & Refill).
11. Install A/C compressor (see Workshop Manual procedure 03.05.BE Compre ssor - Air Conditioning -
Renew).
12. Top-up PAS fluid.
13. Start and run engine, operate steering lock to lock x2.
14. Top-up PAS fluid.
Power Assisted Steering (PAS) Rack -
Remove and Install
Removal
1. Disconnect the battery ground cable.
2. Remove the front undertray (refer to Workshop Manual Procedure 01.02.NB - Front Undertray).
3. Remove the front wheels and tyres (refer to Workshop Manual Procedure 04.04.ED - Wheel and Tyre - Pair).
4. Remove the front right side wheel-arch liner (refer to Workshop Manual Procedure 01.02.GB - Front Right
Side Wheel-Arch Liner).
5. Put a container in position under the oil tank to collect oil.
6. Remove the drain plug from the oil tank.
Figure 1
7. Let the oil drain into the container.
8. Install and tighten the drain plug into the oil tank (refer to Figure 1).
9. Remove the container.
10. Lower the vehicle.
11. Remove the radiator closing panel (refer to Workshop Manual Procedure 01.02.AA - Radiator Closing Panel).
Repair Operation Time (ROT)
Repair Operation Time (ROT)
Repair Operation Time (ROT)
ItemCode
Power Assisted Steering (PAS) Rack -
Remove and Install 11.02.AA

Power Steering (11.02)
Steering (11.00)
Issue 5, January 2010 Workshop Manual 11-2-7
57. Remove the three bolts that attach the PAS rack to the front subframe.
Figure 25
58. Remove the PAS rack.
Install
1. Put the PAS rack into position.
Figure 26
2. Install and tighten the three bolts that attach the PAS rack to the front subframe.
Figure 27
3. Remove and discard the caps from the PAS pipes and the PAS rack. 4. Install two new O-ring seals onto the PAS pipes.
Figure 28
5. Connect the PAS pipes to the PAS rack.
Figure 29
6. Lower the vehicle.
7. Install and torque the screw that attaches the PAS pipes
to the PAS rack.
Figure 30
8. Lift the vehicle.