2010 ASTON MARTIN V8 VANTAGE drain bolt

Cooling System (03.03)
Engine (03.00)3-3-10 Workshop Manual Issue 5, Janauary 2010
12. Remove coolant manifold (bolts x4) (refer to Figure 9).
Figure 9
13. Remove old seals.
14. Remove bracket breather (bolt x1, nut x2).
Installation
1. Install bracket breather (bolt x1, nuts x2) (torque).
2. Clean gasket faces.
3. Install new seals.
4. Install coolant manifold (bolts x4) (torque).
5. Install 4th bolt of vacuum tank bracket fixing (torque).
6. Install harness clips (x2).
7. Connect coolant temp multiplug.
8. Connect separator hose (clip x1).
9. Connect breather hose (quickfit).
10. Connect heater return hose (clip x1).
11. Connect heater feed hose (clip x1).
12. Connect expansion tank feed hose (quickfit).
13. Disconnect top hose (clip x1).
14. Connect bottom hose (clip x1).
15. Install reservoir bracket asse mbly - vacuum system (refer
to Workshop Manual procedu re 03.08.AE Reservoir and
Bracket Assembly - Vacuum System - Renew).
Engine Electric Co olant Temperature
Sensor - Renew
Removal
1. Drain Cooling system (refer to Workshop Manual procedure 03.03.AD Coolant - Drain and Refill).
2. Disconnect breather pipe qu ickfits (x2) from air cleaner
duct.
3. Remove throttle body duct for access. (clips x3). 4. Remove pump pulley bolts (x3) (refer to Figure 1).
Figure 1
5. Release tensioner and slip belt from idler (refer to Figure
2).
Figure 2
6. Remove pump pulley.
7. Disconnect throttle body coolant hose (refer to Figure 3).
Figure 3
Repair Operation Time (ROT)
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Cooling System (03.03)
Engine (03.00)
Issue 5, Janauary 2010 Workshop Manual 3-3-11
8. Remove sensor attachment clip (refer to Figure 4).
Figure 4
9. Remove sensor from housing with multiplug, then disconnect (refer to Figure 5)
.
Figure 5
Installation
1. Clean seal area.
2. Install sensor, with multiplug connected.
3. Install sensor attachment clip.
4. Connect throttle body coolant hose.
5. Fit pulley to pump with bolts.
6. Release tensioner and slip belt on idler.
7. Torque pulley bolts (bolt x3).
8. Install throttle body duct.
9. Connect breather pipe quickf its (x2) to air cleaner duct.
10. Refill cooling system (refer to Workshop Manual procedure 03.03.AD Coolant - Drain and Refill).
Thermostat Cover - Renew
Removal
1. Drain Coolant (refer to Workshop Manual procedure 03.03.AD Coolant - Drain and Refill).
2. Release breather valve (bolt x1) and tie aside.
3. Disconnect breather pipe qu ickfits (x2) from air cleaner
duct.
4. Remove throttle body duct for access. (clips x3).
5. Unclip engine harness for access (x4).
6. Remove one end of engine breather hoses for access (x3).
7. Remove breather valve bracket for access (nuts x2 bolt x1).
8. Remove thermostat housing from manifold (bolt x3).
9. Remove thermostat and sealing ring.
Installation
1. Install thermostat and sealing ring .
2. Install thermostat housing (torque).
3. Install breather valve bracket.
4. Install breather hoses (x3) and clip.
5. Clip engine harness.
6. Install breather valve.
7. Install throttle body duct.
8. Connect breather pipe quickf its (x2) to air cleaner duct.
9. Refill coolant (refer to Workshop Manual procedure 03.03.AD Coolant - Drain and Refill).
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Repair Operation Time (ROT)

Fuel Charging System (03.04)
Engine (03.00)3-4-2 Workshop Manual May 2007
Maintenance
Fuel Rails - Renew
Removal
1. Depressurise fuel rail (see Workshop Manual procedure
10.01.EK Fuel System - Depressurise).
2. Coolant drain (see Workshop Manual procedure 03.03.AD Coolant - Drain and Refill).
3. Remove cross brace (bolts x4).
Removal RH Side
4. Remove coil cover.
5. Disconnect breather hose (quick fit) move aside.
6. Release harness fir tree clips (x3) from cylinder head and move aside.
7. Remove fuse box bracket fixings (bolt and nut) (allows movement).
8. Remove ECM (see Workshop Manual procedure 03.14.BB Engine Control Module - RH Renew).
9. Remove battery lead (1x nu t and rubber cover) from
fuse box (2x leads).
10. Remove multiplugs (x10) from fusebox.
11. Remove earth terminal (1x nut and rubber cover) from fusebox.
12. Remove fuse box from bracket (bolt x2).
13. Release harness fir tree clips (x3) from engine bracket.
14. Feed harness from inner wing and over engine to gain access to cam cover.
15. Remove purge pipe P-clip (bolt x1) and move pipe
aside.
16. Remove harness bracket from engine (bolts x2, nut x1).
17. Release fuel feed hose from rail (clip x1) and move aside.
18. Disconnect heater hose from pipe (quick fit).
19. Release heater hose (clips x2) and EGR vacuum line (clips x2) from bracket.
20. Release harness from coolant pipe bracket (fir tree x3).
21. Disconnect EGR (x1), fuel rail pressure sensor (x1) and injector multiplugs (x4), move harness aside.
22. Remove coolant pipe bracket (nuts x2 and bolts x2).
23. Disconnect EGR vac pipe from sensor and manifold, move aside.
Removal LH Side
24. Remove corner cross brace.
25. Remove coil cover.
26. Disconnect breather hoses from cam cover (x2) for access.
27. Disconnect purge line from manifold (quickfit) and support clip for access. 28. Disconnect heater hose
from pipe (quick fit).
29. Release heater hose (x2) and throttle body hose (x2) from support bracket.
30. Remove booster hose from manifold and support clip.
31. Remove harness support bracket (bolt x1, nut x2) release harness clips (fir tree x3).
32. Release pipe support bracket (nuts x2, bolts x2) move aside.
33. Disconnect injector multiplugs (x4).
34. Unclip injector harness from cam cover (x2).
35. Disconnect IAT multiplug.
36. Disconnect breather hose from manifold (quickfit).
Removal - Manifold From Vehicle
37. Disconnect manifold heating hoses (x2).
38. Disconnect throttle body multiplug and harness clip.
39. Disconnect breather pipe qu ickfits (x2) from air cleaner
duct.
40. Disconnect air cleaner duct (clip x1).
41. Disconnect EGR vacuum hose.
42. Disconnect EGR pipe union and tie aside.
43. Remove manifold bolts (x 10).
44. Remove bolts (x2) bracket to manifold (rear).
45. Move manifold (2x people) forward, remove bolt for purge line T-clip, remove manifold.
46. Remove gaskets and clean mating faces.
Removal - Manifold Parts
47. Remove Injector to rail clips (x8) (see Figure 1).
Figure 1
48. Remove fuel rail (bolts x4).
Installation
1. Install clips and new O-rings to injectors.
2. Install fuel rail (bolts x4).
Repair Operation Time (ROT)
WAR NI NG
THE INTAKE MANIFOLD IS HEAVY. TO AVOID
PERSONAL INJURY OR DAMAGE TO THE INTAKE MANIFOLD, INTAKE MANIFOLD REMOVAL /
ISTALLATION IS A TWO PERSON OPERATION.
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Fuel Charging System (03.04)
Engine (03.00)
May 2007 Workshop Manual 3-4-3
Installation Manifold to Vehicle
3. Install new gaskets to cylinder block (glue in place).
4. Install manifold (allowing access to install bolt for purge
line P-clip).
5. Install manifold bolts (x10) (torque and tightening sequence).
6. Install bolts (x2) bracket to manifold (rear).
7. Connect EGR pipe union.
8. Connect EGR vacuum hose.
9. Connect air cleaner duct (clip x1).
10. Connect breather pipe quickf its (x2) to air cleaner duct.
11. Connect throttle body multiplug and harness clip.
12. Connect manifold heating hoses (x2).
Installation RH Side
13. Connect EGR vac pipe to sensor and manifold.
14. Install coolant pipe bracket (bolt x2, nut x2).
15. Connect EGR (x1), fuel rail pressure sensor (x1) and
injector multiplugs (x4).
16. Refit harness to coolant pipe bracket (fir tree x3).
17. Connect heater hose to pipe (quick fit).
18. Refit heater hose (clipx2) and EGR vacuum lines (clips x2) to bracket.
19. Install fuel feed pipe.
20. Install purge pipe P-clip.
21. Install harness bracket to engine.
22. Feed harness into inner wing area.
23. Install fusebox to bracket.
24. Install earth lead to fusebox.
25. Install battery lead to fusebox (1x nut and rubber cover).
26. Install multiplugs to fuse box.
27. Install fusebox bracket fixings.
28. Refit harness fir tree clips to cylinder head.
29. Refit engine breather hose.
30. Install VVT solenoid multip lug, position coil and CMP
harness (1x edge clip).
31. Install ECM (see Workshop Manual procedure 03.14.BB XREF: 319 Engine Control Module - RH Renew
32. Install coil cover.
Installation LH Side
33. Connect breather hose to manifold (quickfit).
34. Connect IAT multiplug.
35. Unclip injector harness from cam cover (x2).
36. Connect injector multiplugs (x4).
37. Install pipe support bracket (nuts x2, bolts x2).
38. Install harness support bracket (bolt x1, nut x2) release harness clips (fir tree x3).
39. Connect booster hose to manifold and support clip. 40. Connect heater hose from pipe (quick fit).
41. Install heater hose (x2) and throttle body hose (x2) from
support bracket.
42. Connect purge line to manifold and into support clip.
43. Connect breather hoses (x2) to cam cover.
44. Install coil cover.
45. Install corner cross brace (t orque bolts with vehicle on
level ground).
46. Refill coolant (see Workshop Manual procedure 03.03.AD Coolant - Drain and Refill).
47. Install cross brace (torque bolts with vehicle on level
ground).
Fuel Injection Pressure Sensor - Renew
Removal
1. Depressurise fuel rail (see Workshop Manual procedure 10.01.EK Fuel System - Depressurise).
2. Disconnect vacuum hose.
3. Remove sensor from fuel rail (bolts x2).
4. Disconnect multiplug.
Installation
1. Install sensor to fuel rail (bolts x2) (torque).
2. Connect multiplug.
3. Connect vacuum hose.
Fuel Temperature Sensor - Renew
Removal
1. Depressurise fuel rail (see Workshop Manual procedure 10.01.EK Fuel System - Depressurise).
2. Disconnect vacuum hose.
3. Remove sensor from fuel rail (bolts x2).
4. Disconnect multiplug.
Installation
1. Install sensor to fuel rail (bolts x2) (torque).
2. Connect multiplug.
3. Connect vacuum hose.
WA R N I N G
THE INTAKE MANIFOLD IS HEAVY. TO AVOID
PERSONAL INJURY OR DAMAGE TO THE INTAKE MANIFOLD, INTAKE MANIFOLD REMOVAL /
ISTALLATION IS A TWO PERSON OPERATION.
Installation Not Handed
Repair Operation Time (ROT)
Repair Operation Time (ROT)

Emission Control (03.08)
Engine (03.00)3-8-2 Workshop Manual October 2005
6. Disconnect hose from engine (quickfit) and remove
hose.
Installation
1. Connect hose to engine (quickfit).
2. Clip hose to bracket.
3. Remove drain container.
4. Lower vehicle on ramp.
5. Install hose to oil separator (quickfit).
6. Install throttle body to air cleaner duct (clip x1).
7. Fill tank with approximately amount of displaced oil and replace cap.
8. Use handbook procedure to check oil level.
Oil Separator Assembly-Renew
Removal
1. Release clip and disconnect air cleaner duct from throttle body.
2. Disconnect hoses from oil separator (clips x2).
3. Remove separator (bolt x1) (place cloth to catch oil)
Installation
1. Install separator (bolt x1) (torque).
2. Install hoses to oil separator (clips x2).
3. Install throttle body to air cleaner duct (clip x1).
4. Use handbook procedure to check oil level.
Emissions Separator Hose-Renew
Removal
1. Move throttle body to air cleaner duct for access (clip x1).
2. Disconnect hose from oil separator (clips x1).
3. Disconnect hose from engi ne and remove (clips x1).
Installation
1. Connect hose to engine (clips x1).
2. Install hose to oil separator (clips x1).
3. Install throttle body to air cleaner duct (clip x1).
4. Use handbook procedure to check oil level.
Secondary Air Injection Pump and
Bracket Assembly-Renew
Removal
1. Disconnect vehicle battery. 2. Remove inlet manifold assembly (see Workshop Manual
procedure 03.01.BA Manifold Assembly - Intake Upper
- Renew).
3. Disconnect breather tube to secondary air pump (quickfit).
4. Disconnect vacuum tube from solenoid valve.
5. Disconnect vacuum tubes (x2) from actuator valves.
6. Loosen unions and disconnect secondary air injection tubes (x2).
7. Disconnect multiplug, air injection pump. Release multiplug from mounting bracket.
8. Release harness and vacuum tube fir tree clips (x6) from mounting bracket.
9. Remove bolts (x3), securing secondary air injection pump assembly to engine.
10. Remove secondary air injection pump assembly.
Installation
1. Position secondary air injection pump assembly, install and torque tighten bolts (x3).
2. Secure harness and vacuum tube fir tree clips (x6) in
mounting bracket.
3. Secure multiplug in bracket, connect multiplug.
4. Connect and torque tighten secondary air tube unions (x2).
5. Connect vacuum tubes to solenoid and actuator valves (x3).
6. Connect breather tube to secondary air injection pump.
7. Install inlet manifold assembly (see Workshop Manual procedure 03.01.BA Manifold Assembly - Intake Upper
- Renew).
8. Connect vehicle battery.
PCV Valve Assembly-Renew
Removal
1. Disconnect breather tube from PCV valve.
2. Remove bolts (x2) securing PCV valve, remove PCV valve.
Installation
1. Clean PCV valve and mating face.
2. Install PCV valve, install and torque tighten bolts (x2).
3. Connect breather tube to PCV valve.
Crank Vent Hose-Renew
Removal
1. Disconnect hose from cam cover (quickfit).
Repair Operation Time (ROT)
Repair Operation Time (ROT)
Repair Operation Time (ROT)
Repair Operation Time (ROT)
ItemCode
PCV Valve Assembly-Renew 03.08.DC
Repair Operation Time (ROT)
ItemCode
Crank Vent Hose-Renew 03.08.DD

Engine Sealing (03.10)
Engine (03.00)
Issue 5, Janauary 2010 Workshop Manual 3-10-1
Engine (03.00)
Engine Sealing (03.10)
Specifications
Maintenance
Engine Timing Cover - Renew
1. Remove the front subframe (refer to Workshop Manual procedure 02.01.BA Subframe Assembly - Front -
Remove for Access and Refit).
2. Put an applicable container in position under the engine
to collect drained oil.
3. Remove the sump drain plug and drain the oil from the engine.
4. Remove the oil tank assembly (refer to Workshop Manual procedure 03.02.CA Tank Assembly - Oil
Cooler - Renew).
5. Drain cooling system (refer to Workshop Manual procedure 03.03.AD Coolant - Drain and Refill).
6. Remove the left cam cover (Refer to ’Left Side Cam Cover - Remove and Install’, page 3-10-4) 7. Remove the outer and inner seals from the left cam
cover.
8. Remove the right cam cover (Refer to ’Right Side Cam Cover - Remove and Install’, page 3-10-9).
9. Remove the outer and inner seals from the right cam cover.
10. Release the clips and disconnect the two coolant hoses from the coolant manifold.
11. Release the clip and disconnect the hose from oil the separator.
12. Remove the four M6 Torx screws that attach the coolant manifold to the cylinder heads (Refer to Figure 1).
Figure 1
13. Release the coolant manifold from the coolant pipe.
14. Disconnect the electrical connector for the temperature sensor.
15. Remove the coolant manifold.
16. Remove and discard the two O-rings from the manifold.
17. Loosen the three M6 attachment screws for the water pump pulley (Refer to Figure 2).
Figure 2
18. Turn the auxiliary drive be lt tensioner to release the
tension from the drive belt.
19. Remove the drive belt.
20. Remove the three M6 screws that attach the water pump pulley and remove the pulley.
Torque Figures
DescriptionNm.lb./ft.
Cam cover 10 7
Dipstick tube 6 4
Timing cover:
Bolts 1 to 7, 9 to 18 and 20 to 27
Bolts 8 and 19
12

10
9

7
Crankshaft pulley bolt 320 236
Alternator mounting bracket 21 15.5
Alternator 40 30
Coolant manifold 9 6.5
Coolant pump 12 9
Coolant pump pulley 10 + 45° 7 + 45°
PAS pump 21 15.5
Accessory drive belt idler pulleys 40 30
Accessory drive be lt tensioner 40 30
Heater hose brackets:
M6 Bolts
M5 Nuts
12

5
9

3.7
Harness support brackets:
M5 Nut
M6 Screw
M8 Screw
5

10
25
3.7

7
18.5
Repair Operation Time (ROT)
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Engine Sealing (03.10)
Engine (03.00)3-10-2 Workshop Manual Issue 5, Janauary 2010
21. Remove the M10 bolt that attaches the auxiliary drive belt tensioner and remove tensioner (Refer to Figure 3).
Figure 3
22. Remove the two bolts that attach the inspection cover to lower crankcase and remove the cover.
23. Install the tool (303-1185) to hold the flywheel. Install and tighten the two bolts.
24. Remove and discard the M16 screw that attaches the crankshaft pulley.
25. Install the thrust-button of tool (303 -1186) into crankshaft.
26. Put the tool into the pulley.
27. Attach the tool with the two bolts.
28. Turn the centre bolt clockwise to withdraw the pulley from the crankshaft.
29. Collect the crankshaft pulley, locking ring and the thrust button for the special tool.
30. Remove the special tool from the pulley.
31. Remove and discard the O-ring seal from the pulley.
32. Remove the bolt that attaches the alternator idler pulley and remove the pulley.
33. Remove the bolt that attaches the idler pulley for the air- conditioning compressor and remove the pulley.
34. Put an applicable container under the oil filter to collect drained oil.
35. Remove the oil filter.
36. Release the oil separator drain tube from the timing cover.
37. Release the clip for the oil separator drain tube from the bracket.
38. Release the cover for the battery cable from the alternator. 39. Remove the nut that attaches the battery cable to the
alternator and remove the cable. (Refer to Figure 4).
Figure 4
40. Disconnect the electrical connector from the alternator.
41. Remove the M8 bolt that attaches the top of the alternator.
42. Remove the M10 bolt and the nut that attaches the bottom of the alternator and remove the alternator.
43. Remove the three Torx bolts that attach the alternator mounting bracket to the cylinder block.
44. Remove the bracket (Refer to Figure 5).
Figure 5
45. Remove the three M8 bolts that attach the PAS pump to the mounting bracket and move the pump away.
WAR NI NG
DO NOT GET USED ENGINE OIL ON YOUR SKIN.
USED ENGINE OIL CAN BE HARMFUL.
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Engine Sealing (03.10)
Engine (03.00)
Issue 5, Janauary 2010 Workshop Manual 3-10-3
46. Remove the four M8 Torx bolts that attach the PAS pump mounting bracket to the cylinder block and
remove the bracket (refer to Figure 6).
Figure 6
47. Remove the 27 M6 bolts that attach the timing cover to the engine.
48. Collect the bracket for the oil separator drain tube.
49. Remove the timing cover.
50. Remove the outer and inner rubber seals from timing cover (Refer to Figure 7).
Figure 7
51. Remove the front crankshaft oil seal from the timing
cover.
Install
1. Examine the condition of the seal in the John Guest cartridge connector for the oil return pipe. If there are
signs that the connector has leaked, install a new John
Guest cartridge kit (Refer to ’John Guest Cartridge in the
Engine Timing Cover - Repair’, page 3-10-14).
2. Clean the timing cover and the mating face on the engine. 3. Install the inner and outer seals to the timing cover.
4. Apply 3mm x 12mm beads of sealant to the eight joints
on the engine.
5. Install the timing cover. Put the oil separator drain tube bracket in position and install the 27 M6 bolts..
6. Torque the 27 bolts in the sequence shown in Figure 8.
Figure 8
7. Use tool (303-750) to install the front crankshaft oil seal.
8. Remove the special tool and the seal protector.
9. Use an M16 x 2 plug tap to clean the thread in the crankshaft.
10. Clean the crankshaft pulley and mating face on the crankshaft.
11. Lubricate and install a new O-ring seal in the crankshaft pulley.
12. Examine the crankshaft pulley and the taper collet for damage. Replace all damaged parts.
13. Install the crankshaft pulley, taper collet and a new pulley bolt.
14. Torque tighten the crankshaft pulley bolt.
15. Remove the special tool (303-1185) from the crankcase.
16. Install the inspection cover to the lower crankcase, install and tighten the two attachment bolts.
17. Install the PAS pump mounting bracket. install and torque tighten the four M8 Torx bolts.
18. Install the PAS pump. Install and torque the three M8 bolts.
19. Install the alternator mounting bracket. Install and torque tighten the three M8 Torx bolts.
WA R N I N G
DO NOT GET USED ENGINE OIL ON YOUR SKIN.
USED ENGINE OIL CAN BE HARMFUL.
Caution
Make sure the cranks haft front oil seal mating faces are
clean and dry.
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A0310245
Caution
Do not remove the crankshaft front oil seal protector
until the oil seal is correctly installed.
Caution
Clean the thread in the cran kshaft before you install a
new crankshaft pulley bolt. If you do not you can not apply the correct torque to the bolt.