2010 ASTON MARTIN V8 VANTAGE Workshop Manual

Engine Assembly (03.00)
Engine (03.00)
Issue 5, January 2010 Workshop Manual 3-0-9
51. Remove fuse box bracket fixings (bolt and nut) (allows movement) (refer to Figure 15).
52. Remove battery lead (1x nut and rubber cover) from fuse box (2x leads).
53. Remove multiplugs (x10) from fusebox.
54. Remove earth terminal (1x nut and rubber cover) from fusebox (refer to Figure 16).
55. Remove fuse box from bracket (bolt x2).
56. Feed harness over engine. 57. Remove starter cable from floor stud (nut x1) (refer to
Figure 17).
58. Disconnect multiplugs (x3) RH side of engine bay (refer to Figure 18).
59. Remove earth wires from terminals (nuts x 3).
Figure 15
Figure 16
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Figure 17
Figure 18
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Engine Assembly (03.00)
Engine (03.00)3-0-10 Workshop Manual Issue 5, January 2010
60. Disconnect multiplugs (x4) from inside of vehicle RH side of I.P. (refer to Figure 19).
61. Release grommet from body, feed harness from inside of vehicle.
62. Release harness from clips (x11) and position over engine.
Purge Removal
63. Remove bottom screws (x2) and loosen top screw of washer bottle.
64. Disconnect purge pipe from purge valve (move washer
bottle aside).
65. Release pipe from support clips (x2) and move pipe over engine.
Fuel Pipe Removal
66. Remove fuel hose from rail (clip x1).
Clutch Pipe Removal
67. Remove clutch metal pipe from flexible.
68. Remove flexible hose grommet from support bracket.
Subframe/Engine Removal
69. Remove undertray.
70. Mark subframe position.
71. Remove harness clips (x2).
72. Remove load level sensor from subframe (nut and bolt).
73. Support torque tube with transmission jack.
74. Position trolley, support subframe, remove bolts (x12)
raise vehicle.
75. Ensure A/C HP pipe is clear of engine as body is raised.
Installation
Install Subframe/Engine
1. Ensure A/C HP pipe is co rrect position as body is
lowered. 2. Install subframe to body (refer to Figure 20).
3. Remove transmission jack.
4. Install harness clips (x2).
5. Install load level sensor.
6. Install undertray.
7. Lower ramp.
Cooling Install
8. Connect top hose and clip to body (refer to Figure 21).
Figure 19
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Figure 20
Figure 21
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Engine Assembly (03.00)
Engine (03.00)
Issue 5, January 2010 Workshop Manual 3-0-11
9. Connect bottom hose (refer to Figure 22).
10. Connect expansion tank to engine hose.
11. Connect heater feed hose (quickfit) (refer to Figure 23).
12. Connect heater return hose (quickfit).
13. Connect expansion tank to engine (bleed) hose and body clips (x2).
14. Refill coolant (refer to Workshop Manual procedure 03.03.AD Coolant - Drain and Refill).
Booster Hose Install
15. Install vacuum hose to booster.
P.A.S. Install
16. Connect H.P. pipe to pump (renew O-ring).
17. Install PAS reservoir to bracket (bolt x1). 18. Install hoses (x2) to PAS reservoir (refer to Figure 24).
19. Install suction hose to body P-clip (bolt x1).
20. Install pipes to steering rack
(bolt x1) and fit new O-rings
(x2).
Oil Tank Install
21. Connect oil pipe from oil thermostat.
22. Install oil tank (bolts x4) (refer to Figure 25).
Figure 22
Figure 23
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Figure 24
Figure 25
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Engine Assembly (03.00)
Engine (03.00)3-0-12 Workshop Manual Issue 5, January 2010
23. Connect breather hose to tank (quickfit) (refer to Figure
26).
24. Connect oil pipes to tank (x3) (refer to Figure 27).
25. Fill tank with approximatel y amount of displaced oil and
replace cap.
A/C Install
26. Fit new O-rings to A/C pipes (lubricate). 27. Install pipes to compressor (b
olts x2) (refer to Figure 28).
28. Install bolt (x1) HP pipe to bracket (refer to Figure 29).
29. Install bolts (x2) LP pipe to body P-clips (refer to Figure 30).
30. Connect compressor clutch multiplug.
Figure 26
Figure 27
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Figure 28
Figure 29
Figure30
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Engine Assembly (03.00)
Engine (03.00)
Issue 5, January 2010 Workshop Manual 3-0-13
31. Recharge refrigerant (refer to Workshop Manual procedure 12.03.FA Refrigerant Gas - Recover/Recharge
- Renew).
Steering Install
32. Connect steering column link to steering rack (bolt x1) (refer to Figure 31).
Figure 31
Electrical Install
33. Feed harness into inner wing area (refer to Figure 32).
Figure 32
34. Install fusebox to bracket.
35. Install earth lead to fusebox.
36. Install battery lead to fusebox (1x nut and rubber cover). 37. Install multiplugs to fuse box (refer to Figure 33).
Figure 33
38. Install fusebox bracket fixings (refer to Figure 34).
Figure 34
39. Install ECM and connect mu
ltiplugs to ECM (through
cover plate) (refer to Figure 35).
Figure 35
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Engine Assembly (03.00)
Engine (03.00)3-0-14 Workshop Manual Issue 5, January 2010
40. Secure ECM and cover plate with bolts (x3) (refer to Figure 36).
41. Reclip ECM harness.
42. Reclip repeater light and screen wash system harness.
43. Connect repeater light multiplug.
44. Install starter cable to floor st ud (nut x1) (refer to Figure
37). 45. Feed harness to inside of vehicle install grommet to
body (refer to Figure 38).
46. Position harness to body and install clips (x11).
47. Connect multiplugs (x4) from inside of vehicle RH side of I.P. (refer to Figure 39).
48. Install earth wires to terminals (nuts x13).
Figure36
Figure 37
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Figure 38
Figure 39
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Engine Assembly (03.00)
Engine (03.00)
Issue 5, January 2010 Workshop Manual 3-0-15
49. Connect multiplugs (x3) RH side of engine bay (refer to Figure 40).
Purge Install
50. Connect purge pipe to purge valve.
51. Install bottom screws (x2) and tighten top screw of washer bottle.
52. Move pipe into position and install pipe to support clips (x2).
Fuel Install
53. Install fuel hose to rail (clip x1).
Clutch Pipe Install
54. Install clutch metal pipe from flexible.
55. Install flexible hose grommet to support bracket.
56. Bleed clutch.
Suspension Install
57. Install front springs and dampers. (refer to Workshop Manual procedure 04.03.AA Spring and Damper
Assembly - Front Pair - Renew).
58. Install RH wheel arch liner (refer to Workshop Manual procedure 01.02.GB Wheel Arch Liner - Front - RH -
Renew
59. Install LH wheel arch liner (refer to Workshop Manual procedure 01.02.FB Wheel Arch Liner - Front - LH -
Renew).
60. Install bottom arms (nut and bolt x4) with uprights and top arm.
61. Install level sens or link to bottom arm (nut x1).
62. Connect level sensor multiplug.
63. Connect track rod ends (nut x2).
64. Install anti-roll bar to links (nuts x2).
65. Install brake discs.
66. Install brake callipers.
67. Install road wheel/s Throttle Duct Install
68. Connect breather pipe quic
kfits (x2) from air cleaner
duct (refer to Figure 41).
69. Install throttle body duct (refer to Figure 42).
General Install
70. Remove strap - vehicle to ramp (front).
71. Lower vehicle on ramp.
72. Connect vehicle battery.
73. Top-up PAS fluid.
74. 4 wheel alignment check/adjust (refer to Workshop Manual procedure 04.00.AD 4 Wheel Alignment -
Check and Adjust).
75. Install transmission (refer to Workshop Manual procedure 07.03.AA Transaxle Assembly - Manual -
Remove for Access and Refit).
76. Use handbook procedure to check oil level.
Figure 40
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Figure 41
Figure 42
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Engine Assembly (03.00)
Engine (03.00)3-0-16 Workshop Manual Issue 5, January 2010