2010 ASTON MARTIN V8 VANTAGE ECU

Manual Control System (07.06)
Transmission (07.00)
May 2007 Workshop Manual 7-6-1
Transmission (07.00)
Manual Control System (07.06)
Maintenance
Gearshift Assembly Mechanism-Renew
Removal
1. Remove panel assembly - console (see Workshop Manual procedure 01.12.DB Panel Assembly Console -
Renew).
2. Using tool (308 - 642), release selector cable ball joints (x2) from gear lever mechanism.
3. Remove screws (x6), securi ng gear lever mechanism to
housing.
4. Remove gearshift assembly mechanism.
5. Remove gear knob, collect gaiter.
Installation
1. Clean gearshift mechanism.
2. Lubricate gearshift mechanism with recommended grease.
3. Install gearshift mechanism, install and tighten screws
(x6).
4. Install selector cables to gearshift mechanism.
5. Install panel assembly - console (see Workshop Manual procedure 01.12.DB Panel Assembly Console - Renew).
6. Install gear lever gaiter, install gear knob.
Transmission Gearshift Cable Assembly-
Renew
Removal
1. Disconnect vehicle battery.
2. Remove panel assembly - console.
3. Using tool 308 - 642, release selector cable ball joint from gear lever mechanism.
4. Remove horseshoe clip secu ring selector to bracket.
5. Raise vehicle on ramp and secure with straps. 6. Remove road wheel(s).
7. Remove rear exhaust muffl
er (see Workshop Manual
procedure 09.00.KA Silencer and Bypass Valve
Assembly - Re move for Access and Refit
8. Remove bolts (x4), subframe cross brace.
9. Loosen clamp nuts (x2), release centre pipe from both catalysts.
10. Remove centre pipe and rear exhaust pipes as an
assembly.
11. Remove bolts (x4), centre heatshield to body, remove heatshield.
12. Remove bolts (x8), shear plate to body, remove shear plate.
13. Remove bolt securing earth lead to transaxle.
14. Mark drive shaft to differential flanges for assembly purposes.
15. Remove and discard Allen bolts (x12), collect plates (x6), drive shaft flanges to transaxle.
16. Release drive shafts from transaxle and position aside.
17. Position drain container to collect oil spillage.
18. Loosen unions and disconnect oil cooler pipes (x2) from
transaxle interconnecting pipes. Plug pipe connections
(x4).
19. Remove drain container.
20. Remove nuts (x2), hydra mounts to subframe mountings.
21. Position hydraulic lifter to support transaxle.
22. Remove and discard bolts (x8 (4 each side), mounting brackets to transaxle. Remove mounting brackets with
hydra mounts.
23. Release reverse lamp switch multiplug from bracket, disconnect multiplug.
24. Lower transaxle sufficiently and use tool (308 - 642) to release selector cable ball joint from selector lever.
25. Remove horse shoe clip securing selector cable to mounting bracket, remove selector cable assembly.
Repair Operation Time (ROT)
Repair Operation Time (ROT)
WA R N I N G
TO AVOID PERSONAL INJURY, I.E. SEVERE BURNS TO
THE SKIN, ALLOW EXHAUST SYSTEM TO COOL DOWN BEFORE REMOVING EXHAUST SYSTEM COMPONENTS.
WA R N I N G
OBSERVE ALL TRANSAXLE OIL MANUFACTURERS SAFETY INSTRUCTIONS WHEN HANDLING
COMPONENTS THAT HAVE BEEN IN CONTACT WITH
TRANSAXLE OIL.
Caution
Plug oil cooler connections to prevent ingress of dirt or moisture into the system.
Caution
Ensure that the service tool No. 0308 - 642 is used to
release selector cable ball joints from selector levers.

Manual Control System (07.06)
Transmission (07.00)7-6-2 Workshop Manual May 2007
Installation
1. Install selector cable, connect to ball joint, install horseshoe clip.
2. Connect multiplug to reverse light switch, install multiplug in bracket.
3. Install reverse light harness clip in transaxle.
4. Install transaxle mounting brackets and hydra mounts, install and torque tighten new bolts (x8).
5. Align hydra mounts to subframe, lower lifter, install and torque tighten nuts (x2). Remove lifter.
6. Remove plugs, connect and torque oil cooler unions.
7. Apply thread lock to new Allen bolts.
8. Align drive shafts to transaxle flanges, clean and install plates (x6), install and torque tighten Allen bolts (x12).
9. Position earth lead to transaxle, install and torque tighten bolt.
10. Install shear plate, install bolts (x8), tighten bolts to correct torque.
11. Install centre heatshield, install bolts (x4), tighten bolts to correct torque.
12. Install centre and rear exhaust pipe assembly, align to both catalysts. tighten clamp nuts to correct torque.
13. Install subframe cross brace, install and torque tighten bolts (x4).
14. Install rear exhaust muffler (see Workshop Manual procedure 09.00.KA Silencer and Bypass Valve
Assembly - Remove for Access and Refit).
15. Install road wheel(s).
16. Lower vehicle on ramp, remove securing straps.
17. Position selector cable in bracket, install horseshoe clip.
18. Install selector cable ball jo int to gear lever mechanism.
19. Install panel assembly - console.
20. Connect vehicle battery.
21. Test drive vehicle.
22. Raise vehicle on ramp; Check transaxle oil level.

Automatic Shifting Subsystem (07.11)
Transmission (07.00)
May 2007 Workshop Manual 7-11-1
Transmission (07.00)
Automatic Shifting Subsystem
(07.11)
Maintenance
Transmission Control Module-Renew-
Sportshift Only
Removal
1. Open boot lid.
2. Disconnect vehicle battery.
3. Remove access panel (right-hand side).
4. Release strap securing punctu re repair kit from bracket
and remove.
5. Remove retention clip (b olt x1) and Transmission
Control Module from mounting bracket.
6. Release Transmission Control Module multiplug catches (x2), disconnect Transmission Control Module
multiplugs (x2) and remove.
Installation
1. Install Transmission Control Module and connect multiplugs.
2. Install Transmission Control Module to mounting bracket, secure with retention clip and bolt.
3. Install puncture repair kit to bracket and secure with strap.
4. Install access panel (right-hand side).
5. Connect vehicle battery.
6. Close the boot lid.
Repair Operation Time (ROT)

Clutch Assembly (08.01)
May 2007 Workshop Manual 8-1-3
8. Remove bolts (x8) from flywheel to crankshaft and discard bolts (see Fig. 3).
9. Remove bolts (x2) and collect special tool SKAM14546 OTC.
10. Release flywheel from dowels and remove flywheel.
Installation
1. Clean flywheel and mating face on crankshaft flange.
2. Inspect pilot bearing for wear.
3. Position flywheel and align to dowel(s) on crankshaft flange.
4. Install bolts (x8) and install special tool SKAM14546 OTC to restrain flywheel.
5. Tighten flywheel bolts in the correct sequence.
6. Clean clutch cover and drive plate.
7. Install clutch assembly on flywheel and align to dowels.
8. Install bolts (x8), insert clutch alignment tool and evenly tighten bolts to the correct torque.
9. Remove clutch alignment tool.
10. Remove bolts (x2) and collect tool.
11. Install inspection cover to crankcase and tighten bolts (x2).
12. Install torque tube assembly (see Workshop Manual procedure 05.01.CA Torque Tube Remove for Access
and Refit).
13. Lower vehicle on ramp.
14. Connect vehicle battery.
Slave Clutch Cylinder-Renew
08.00.AC
Removal
1. Disconnect vehicle battery.
2. Raise vehicle on ramp.
3. Remove torque tube (see Workshop Manual procedure 05.01.CA Torque Tube Remove for Access and Refit).
4. Release clips and remove bleed and supply pipes from slave cylinder.
5. Install clips in union
6. Loosen and remove pipe adaptors (x2) from slave cylinder (see Fig. 1).
7. Sportshift Only - Remove bolts (x2) securing clutch
position sensor to slave cylinder.
Fig. 3
Warning
The flywheel is heavy. Ensure the flywheel is supported
before removing.
Warning
The flywheel is heavy. Ensure the flywheel is supported
when installing.
Warning
The clutch assembly is heavy. Ensure the clutch
assembly is supporte d when installing.
Caution
The flywheel and pressure are a balanced assembly. Ensure alignment marks are aligned.

Repair Operation Time (ROT)
Warning
Always disconnect the battery earth (- ve) terminal first.
Warning
When raising the vehicle on a ‘two post’ ramp, ensure
that the rear end of the vehicle is securely strapped to
the ramp. Failure to strap the rear of the vehicle down may lead to the vehicl e falling off the ramp.
Caution
Always plug pipe ends to prevent ingress of dirt or moisture into the system.
Fig. 1


Clutch Assembly (08.01)
8-1-4 Workshop Manual May 2007
8. Remove bolts (x2) that secure slave cylinder to torque tube (see Fig. 2).
9. Remove slave cylinder and collect spacer.
Installation
1. Clean slave cylinder, spacer and pipe adaptors.
2. Install spacer and slave cylinder and tighten bolts (x2).
3. Sportshift Only - Install clutch position sensor to slave
cylinder and secure with bolts.
4. Install pipe adaptors (x2) in slave cylinder.
5. Install bleed and supply pipes onto slave cylinder adaptors (x2) and secure with clips.
6. Install torque tube (see Workshop Manual procedure 05.01.CA Torque Tube Remove for Access and Refit).
7. Bleed clutch (see Workshop Manual procedure 08.00.AF Clutch Hydraulic System - Bleed).
8. Lower vehicle on ramp.
9. Connect vehicle battery.
Clutch Bleed Hose Assembly-Renew
08.00.AD
Removal
1. Raise vehicle on ramp.
2. Coupe Only - Remove deflector - front floor heatshield
(see Workshop Manual proc edure 09.04.AA Heatshield
- Front Floor - Renew).
3. Roadster Only - Remove exhaust sysytem (see
Workshop Manual procedure 09.00.NB Exhaust System
- Excluding manifold/down pipes - Renew). 4.
Roadster Only - Remove grommet sealing clutch bleed
pipe to torque tube.
5. Roadster Only - Position a piece of cloth in torque tube
aperture to collect spring clip (if dropped) and fluid loss.
6. Release clip and disconnect bleed hose from slave cylinder adaptor.
7. Plug slave cylinder to prevent fluid loss.
8. Release and remove bleed pipe assembly from support bracket.
Installation
1. Clean bleed hose assembly.
2. Remove plug from slave cylinder adaptor.
3. Install bleed hose and secure with clip.
4. Install bleed hose in support bracket.
5.Roadster Only - Install grommet sealing clutch bleed
pipe to torque tube.
6. Bleed clutch (see Workshop Manual procedure 08.00.AF Clutch Hydraulic System - Bleed).
7. Roadster Only - Install exhaust sysytem (see Workshop
Manual procedure 09.00.NB Exhaust System -
Excluding manifold/down pipes - Renew).
8. Coupe Only - Install deflector - front floor heatshield
(see Workshop Manual procedure 09.04.AA Heatshield
- Front Floor - Renew).
9. Lower vehicle on ramp.
Clutch Hydraulic System-Bleed-
Sportshift Only
08.00.AE
1. Raise vehicle on ramp.
2. Install Diagnostic tool and navigate to appropriate screen.
3. Position cloth around fluid reservoir to collect any spillage.
4. Remove fluid reservoir cap, en sure fluid level is correct
in reservoir.
5. Clean area around clutch bleed nipple.
6. Remove cap from bleed nipple.
7. Position bleed container containing clean hydraulic fluid, connect hose to bleed nipple.
8. Initiate bleed procedure on Diagnostic tool.
9. Loosen bleed nipple, allow air/fluid to escape and tighten bleed nipple.
10. Repeat procedure until air free fluid emerges.
11. Disconnect bleed hose, remo ve container, install dust
cap to bleed nipple.
12. Top-up fluid reservoir.
Fig. 2Warning
Always connect the battery earth (+ve) terminal first.
Repair Operation Time (ROT)
Before proceeding with the ne xt step, position a piece of
cloth in the torque tu be aperture to collect the spring clip
if dropped.
Caution
Always plug pipe ends to prevent ingress of dirt or moisture into the system.

Repair Operation Time (ROT)
ItemCode
Clutch Hydraulic System-Bleed
Warning
Observe all oil/fluid manufactu rers safety instructions
when handling components th at have been in contact
with transaxle oil.

Clutch Assembly (08.01)
May 2007 Workshop Manual 8-1-5
13. Remove Diagnostic tool.
14. Lower vehicle on ramp.
Clutch Hydraulic System-Bleed
08.00.AF
1. Raise vehicle on ramp.
2. Remove fluid reservoir cap and ensure fluid level is correct.
3. Clean area around clutch bleed nipple.
4. Remove cap from bleed nipple.
5. Position bleed container cont aining clean hydraulic fluid
and connect hose to bleed nipple.
6. Depress clutch pedal to floor 3 times and hold pedal down on third application.
7. Loosen bleed nipple allowing any air/fluid to escape.
8. Tighten bleed nipple.
9. Repeat procedure until air-free fluid emerges.
10. Disconnect bleed hose, remove container and install dust cap to bleed nipple.
11. Top-up fluid reservoir.
12. Lower vehicle on ramp.
Master Cylinder to Slave Cylinder Tube
Assembly-Renew
08.00.AJ
-Sportshift Only
Removal
1. Disconnect vehicle battery. 2. Raise vehicle on ramp.
3. Remove torque tube (see Workshop Manual procedure
05.01.CA Torque Tube - Remo ve for Access & Refit).
4. Remove grommet sealing clutch pipe to torque tube.
5. Remove clip, disconnect clutch pipe from slave cylinder adaptor.
6. Release clip securing transmi ssion harness to clutch pipe
mounting bracket.
7. Release clips (x4) securing clutch pipe to transmission harness.
8 . R e m o v e c l u t c h p i p e f r o m t o r q u e t u b e .
Installation
1. Install clutch pipe to torque tube.
2. Secure clutch pipe to tran smission harness using clips.
3. Secure transmission harne ss to clutch pipe mounting
bracket using clip.
4. Install clip and refit clutch pipe to slave cylinder adaptor.
5. Install grommet sealing clutch pipe to torque tube.
6. Install torque tube (see Workshop Manual procedure 05.01.CA Torque Tube - Remo ve for Access & Refit).
7. Bleed clutch hydraulics (see Workshop Manual procedure 08.00.AE Clut ch Hydraulic System -
Sportshift - Bleed).
8. Lower vehicle on ramp.
9. Connect vehicle battery.
Repair Operation Time (ROT)
Warning
Avoid skin / eye contact or in gestion of clutch fluid. If
skin or eyes are sp lashed with clutch fluid, rinse the
affected area immediately with plenty of water and
obtain medical attention. If clutch fluid is ingested, obtain immediate medical attention.
Caution
Clutch fluid must not be allowed to contact vehicle paint work. Remove spilt clutch fl uid from the paint work by
rinsing away with running water.
Warning
Brake / Clutch fluid is hygroscopic. If kept in opened
containers it will absorb water vapour. Use only brake
fluid from freshly opened co ntainers when topping-up
the brake fluid reservoir.
Before proceeding to the next step, position cloth around
fluid reservoir to collect any spillage.
Repair Operation Time (ROT)
Warning
Always disconnect the battery earth (- ve) terminal first.
Warning
When raising the vehicle on a ‘two post’ ramp, ensure
that the rear end of the vehicle is securely strapped to
the ramp. Failure to strap the rear of the vehicle down may lead to the vehicl e falling off the ramp.
Warning
Observe all oil/fluid manufact urers safety instructions
when handling components that have been in contact with transaxle oil.
Warning
Always connect the battery ea rth (+ve) terminal first.

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.