2010 ASTON MARTIN V8 VANTAGE Sd card

Engine Sealing (03.10)
Engine (03.00)3-10-10 Workshop Manual Issue 5, Janauary 2010
20. Remove the four screws that attach each ignition coil.
21. Remove the four ignition coils.
22. Remove the 14 screws that attach the cam cover to the engine.
23. Remove and discard the seals for the 14 cam cover screws.
24. Remove the cam cover.
25. Remove and discard the O-ring seal for the VVT solenoid.
26. Remove and discard the cam cover gasket.
27. Remove and discard the four O-ring seals from the spark plug wells.
28. Clean the component mating faces.
Install
1. Install four new O-ring seals in the spark plug wells.
2. Install a new O-ring seal for the VVT solenoid.
3. Install a new cam cover gasket.
4. Apply a 12 mm by 3 mm bead of sealant to the tri-joints shown.
Figure C03-10-101
5. Install the cam cover.
6. Install new seals for the 14 cam cover screws. 7. Install and torque the 14 screws that attach the cam
cover to the engine in the sequence shown to 10 Nm.
8. Install the four ignition coils.
9. Install and torque the screw that attaches each of the four ignition coils to 5 Nm.
10. Install the front bracket for the wiring harness.
11. Install the rear bracket for the wiring harness.
12. Install and torque the three screws that attach the rear bracket for the wiring harness to 11 Nm.
13. Install and tighten the two nuts and three screws that attach the front bracket for the wiring harness.
14. Install the purge pipe and he ater pipe into the two clips
on the wiring harness bracket.
15. Put the purge pipe P-clip into the correct position.
16. Install and tighten the screw that attaches the purge pipe P-clip to the cam cover.
17. Use three applicable cable ties to attach the rear of the wiring harness to the front bracket.
18. Install the wiring harness for the injectors into the mounts.
19. Install the fir tree clip that attaches the wiring harness for the ignition coils.
20. Connect the electrical conne ctors to each of the four
ignition coils.
21. Connect the electrical connector to the VVT solenoid.
22. Install the ignition coil cover.
23. Remove and discard the caps from the breather pipes.
24. Install the breather pipes to the cam cover.
25. Install the right side front crush bar for the body reinforcement. (0101AB - Righ t Side Front Crush Bar for
the Body Reinforcement)
26. Install the front crush brace. (0101LC - Front Crush Brace)
Note: When you remo ve the cam cover
attachment screws in th e step that follows,
record their installed positions in the cam
cover.
CAUTION
Tighten the screws gradually and equally in the step
that follows. If you do not, the cam cover gasket can be
damaged.
C03-10-101
Repair Operation Time (ROT)
ItemCode
Cam Cover - Vehicle Set - Remove
and Install 03.10.AW

Engine Sealing (03.10)
Engine (03.00)
Issue 5, Janauary 2010 Workshop Manual 3-10-11
Removal
1. Remove the left side cam cover (Refer to ’Left Side Cam Cover - Remove and Install’, page 3-10-4).
2. Remove the right side cam cover (Refer to ’Right Side Cam Cover - Remove and Install’, page 3-10-9).
Install
1. Install the left side cam cover (Refer to ’Left Side Cam Cover - Remove and Install’, page 3-10-4).
2. Install the right side cam cover (Refer to ’Right Side Cam Cover - Remove and Install’, page 3-10-9).
Engine Timing Cover-Renew (with Engine
Removed
)
Removal
1. Remove the engine assembly (refer Workshop Manual procedure 03.00.AA Engi ne Assembly - Renew).
2. Position drain container.
3. Remove the drain plug and drain the oil from the sump.
4. Remove the left cam cover (Refer to ’Left Side Cam Cover - Remove and Install’, page 3-10-4).
5. Remove the right cam cover (Refer to ’Right Side Cam Cover - Remove and Install’, page 3-10-9).
6. Release the hose clips and disconnect the two coolant hoses from the coolant manifold.
7. Release the hose clip and di sconnect the hose from the
oil separator.
8. Remove the four Torx bolts that attach the coolant manifold to cylinder heads (refer to Figure 1).
Figure 1
9. Release the coolant mani fold from coolant pipe,
disconnect the temperature sensor multiplug.
10. Remove the coolant manifold.
11. Remove and discard the two O-rings from the coolant manifold. 12. Loosen the three water pump pulley bolts (refer to
Figure 2).
Figure 2
13. Use an applicable socket bar to release the auxiliary
drive belt tensioner.
14. Remove the drive belt.
15. Remove the three bolts and remove the water pump pulley.
16. Remove the bolt that attaches the auxiliary drive belt tensioner.
17. Remove the tensioner (refer to Figure 3).
Figure 3
18. Remove the two bolts that attach the inspection cover to the lower crankcase. Remove the cover.
19. Install tool (303-1185) to hold flywheel. Install and tighten the two bolts .
20. Install the thrust button of tool (303 -1186) into the crankshaft.
21. Put the tool in position in the pulley. Attach the tool with the two bolts. Tighten the centre bolt and remove
the pulley from the crankshaft.
22. Collect the crankshaft pulley, locking ring and the special tool thrust button.
23. Remove the special tool from the pulley.
24. Remove and discard the O-ring seal from pulley.
25. Remove the bolt that attaches the alternator idler pulley.
Repair Operation Time (ROT)
A030368
A030553A
A030553

Engine Sealing (03.10)
Engine (03.00)3-10-14 Workshop Manual Issue 5, Janauary 2010
John Guest Cartridge in the Engine
Timing Cover - Repair
Removal
1. Open the bonnet.
2. Raise the vehicle and make it safe.
3. On Roadster models, remove the front undertray (Refer
to ’Centre Undertray - Remove and Install (Roadster
Only)’, page 1-2-1).
4. Put an approved container under the front cover to collect oil.
5. Disconnect the oil drain pipe from the John Guest
cartridge.
6. Let the oil drain.
7. Use a trim tool as a lever to remove the plastic collet from the cartridge.
8. Remove and discard the O-ring from the cartridge.
9. Clean all unwanted oil from the cartridge.
Install
1. Apply a layer of oil to the new O-ring .
2. Carefully install the new O- ring in the cartridge. Make
sure that the O-ring is in the correct position against the
shoulder of the cartridge.
3. Install the new plastic collet into the cartridge.
4. Connect the oil pipe into the cartridge.
5. Clean all unwanted oil from the area around the cartridge.
6. Remove the container of drained oil.
7. On Roadster models, install the front undertray (Refer to ’Centre Undertray - Remove and Install (Roadster
Only)’, page 1-2-1).
8. Lower the vehicle.
9. Remove the cap from the oil tank.
10. Add oil to the oil tank to the correct level.
11. Install the cap on the oil tank.
12. Start and operate the engine for approximately five minutes.
13. Stop the engine.
14. Wait five minutes for the oil to drain back to the sump.
15. Do a check of the oil le vel. Add oil if necessary. 16. Install the oil tank cap.
17. Close the bonnet.
Repair Operation Time (ROT)

Power Conversion (03.11)
Engine (03.00)
May 2007 Workshop Manual 3-11-1
Engine (03.00)
Power Conversion (03.11)
Maintenance
Connecting Rod Bearing-Renew (Engine
Set)
Removal
1. Remove engine oil sump (see Workshop Manual
procedure 03.02.BN Pan - Oil Sump - Remove and Re-
seal).
2. Remove spark plugs (see Workshop Manual procedure 03.07.DB Spark Plugs - Engine Set - Renew).
3. Remove bolts (x8) securing windage tray to engine bedplate, remove windage tray.
4. Mark bearing caps and connecting rods for correct installation.
5. Rotate crankshaft clockwise to access number 1 cylinder connecting rod bolts.
6. Remove bolts securing bearing cap to connecting rod, remove bearing cap (see Figure 1).
Figure 1
7. Install special tools (303-535) to the connecting rod to prevent damage to crankshaft journal.
8. Move connecting rod upwards, remove bearing shell.
9. Record colour code on bearing shell edge. 10. Remove and discard bearing shell from cap.
11. Record colour code on bearing shell edge, discard
bearing shell.
12. Wipe crankshaft journal, connecting rod and bearing cap using a lint free cloth.
13. Inspect crankshaft journal for damage.
14. Check crankshaft journal for ovality using a micrometer and record journal diameters.
Installation
1. Select the correct colour coded bearing shells for each connecting rod crankshaft journal.
2. Install new selective bearing shell in connecting rod.
3. Lubricate crankshaft journal with clean engine oil.
4. Install connecting rod on crankshaft journal.
5. Remove special tools (303-535) from connecting rod.
6. Install new selective bearing shell in bearing cap.
7. Install bearing cap and new bolts (x2), torque tighten bearing cap bolts.
8. Repeat procedure for remaining connecting rod bearings.
9. Install windage tray to engine bedplate, install and torque tighten bolts (x8).
10. Install spark plugs (see Workshop Manual procedure 03.07.DB Spark Plugs - Engine Set - Renew).
11. Install engine oil sump (see Workshop Manual
procedure 03.02.BN Pan - Oil Sump - Remove and re-
seal).
Crankshaft Main Bearing-Renew (Engine
Set)
Removal
1. Remove bolts (x2), inspection cover to lower crankcase, remove cover.
2. Install tool (303-1185) to restrain flywheel, install and tighten bolts (x2).
3. Remove bolts (x6), clutch cover to flywheel.
4. Release clutch cover from dowels (x3), remove clutch cover, collect drive plate.
5. Remove and discard bolts (x8), flywheel to crankshaft flange.
6. Remove bolts (x2), collect tool (303-1185).
Repair Operation Time (ROT)
WA R N I N G
DO NOT GET USED ENGINE OIL ON YOUR SKIN. USED ENGINE OIL CAN BE HARMFUL.
Caution
Pistons, connecting rods an d connecting rod bearings
should be numbered to make sure they are reassembled
in the same position.
Caution
Connecting rod bolts are tor qu
e tightened to yield and
mu st be replaced.
A0311314
Note: Connecting rod bearings ar e a selective fit by colour
code on edge of bearing shell.
Caution
When assembling connecting rods and connecting rod
bearing caps it is imperative that bearing slots and tangs
be located on the same side of the connecting rods.
Repair Operation Time (ROT)

Power Conversion (03.11)
Engine (03.00)3-11-2 Workshop Manual May 2007
7. Release flywheel from dowel, remove flywheel.
8 . R e m o v e e n g i n e s u m p ( s e e Wo r k s h o p M a n u a l p ro c e d u r e
03.02.CN Pan - Oil Sump - Remove and re-seal With
Engine Removed).
9. Remove bolts (x8) securing windage tray to engine bedplate, remove windage tray.
10. Mark bearing caps and connecting rods for correct installation (see Figure 1).
Figure 1
11. Rotate crankshaft clockwise to access number 1 cylinder
connecting rod bolts.
12. Remove and discard bolts (x16) securing bearing caps to connecting rods, remove bearing caps (see Figure 2).
Figure 2
13. Install special tools (303-535) to the connecting rod to prevent damage to crankshaft journal.
14. Carefully push each connecting rod/piston assembly up each cylinder bore.
15. Secure Dial Test Indicator (DTI) on engine bedplate.
16. Push crankshaft fully rearwards. 17. Position DTI probe on cran
kshaft web and zero gauge.
18. Push crankshaft fully forw ards and record reading on
dial gauge.
19. Remove DTI gauge.
20. Noting their fitted positions, remove bolts (x34) securing engine bedplate to cylinder block (see Figure 3).
Figure 3
21. Carefully release and remove engine bedplate from cylinder block (see Figure 4).
Figure 4
22. Carefully remove crankshaft from cylinder block.
23. Remove rear oil seal from crankshaft.
WAR NI NG
DO NOT GET USED ENGINE OIL ON YOUR SKIN.
USED ENGINE OIL CAN BE HARMFUL.
Caution
Connecting rod bolts are tor que tightened to yield and
must be replaced.
A0311329
A0311314
A0311329
A0311329

Power Conversion (03.11)
Engine (03.00)3-11-4 Workshop Manual May 2007
10. Install crankshaft retaining caps (303-534), install and
lightly tighten bolts (x10) (see Figure 8).
Figure 8
11. Install connecting rod bearing caps (x8), install and torque tighten retaining bolts.
12. Remove bolts securing crankshaft retaining caps (303- 534), remove retaining caps (see Figure 9).
Figure 9
13. Apply a 2mm diameter continuous bead of sealant to cylinder block flange ensuring that there are no gaps in
the sealant.
14. Install engine bedplate to cylinder block, install and torque tighten bolts (x34) in the correct sequence.
15. Remove excess sealant from crankshaft rear oil seal
aperture and front face of cylinder block.
16. Clean windage tray.
17. Install windage tray, install and torque tighten bolts (x8). 18. Ensure that oil seal protector is positioned correctly and
install oil seal onto crankshaft flange.
19. Install tool (303-1189) to crankshaft, position nuts on tool against oil seal.
20. Ensure that oil seal and special are parallel to rear of engine.
21. To install oil seal, tighten nuts alternately on tool (303- 1189) until oil seal correctly seated.
22. Remove special tool from crankshaft.
23. Check that the oil se al is located correctly.
24. Clean flywheel and mating face on crankshaft.
25. Install flywheel, align to dowel on crankshaft flange.
26. Install new bolts (x8), install tool (303-1185) to restrain flywheel. Torque tighten bolts (x8) in the correct
sequence.
27. Clean clutch cover and drive plate.
28. Install clutch assembly on flywheel, align to dowels (x3).
29. Install bolts (x6), install clutch alignment tool, evenly torque tighten bolts (x6) in a diagonal sequence.
Remove clutch alignment tool.
30. Remove bolts (x2), collect tool (303-1185).
31. Install inspection cover, install and torque tighten bolts (x2).
32. Install engine sump (see Workshop Manual procedure 03.02.CN Pan - Oil Sump - Remove and Reseal With
Engine Removed).
Crankshaft Assembly-Renew
Removal
1. Remove bolts (x2), inspection cover to lower crankcase, remove cover.
2. Install tool (303-1185) to restrain flywheel, install and tighten bolts (x2).
3. Remove bolts (x6), clutch cover to flywheel.
4. Release clutch cover from dowels (x3), remove clutch cover, collect drive plate.
5. Remove and discard bolts (x8), flywheel to crankshaft flange.
6. Remove bolts (x2), collect tool (303-1185).
7. Release flywheel from dowel, remove flywheel.
8 . R e m o v e e n g i n e s u mp ( s e e Wo r k s h o p M a n u a l p ro c e d u re 03.02.CN Pan - Oil Sump - Remove and Reseal With
Engine Removed).
Caution
Do not lubricate engine bedplate retaining bolts.
Caution
Tighten engine bedplate retaining bolts in the sequence shown.
Caution
Do not rotate crankshaft until all engine bedplate
retaining bolts are tightened to specification.
Caution
Engine bedplate retaining bolts must be tightened
within twenty minutes of applying sealant.
A0311328
A0311328
Caution
Do not use any lubricant on cr ankshaft oil seals or seal
protectors. Make sure all co mponents are clean and dry.
Repair Operation Time (ROT)
ItemCode
Crankshaft Assembly-Renew 03.11.CF
WAR NI NG
DO NOT GET USED ENGINE OIL ON YOUR SKIN.
USED ENGINE OIL CAN BE HARMFUL.

Power Conversion (03.11)
Engine (03.00)
May 2007 Workshop Manual 3-11-7
27. Clean flywheel and mating face on crankshaft.
28. Install flywheel, align to dowel on crankshaft flange.
29. Install new bolts (x8), install tool (303-1185) to restrain
flywheel. Torque tighten bolts (x8) in the correct
sequence.
30. Clean clutch cover and drive plate.
31. Install clutch assembly on fl ywheel, align to dowels (x3).
32. Install bolts (x6), install clutch alignment tool, evenly torque tighten bolts (x6) in a diagonal sequence.
Remove clutch alignment tool.
33. Remove bolts (x2), collect tool (303-1185).
34. Install inspection cover, install and torque tighten bolts (x2).
35. Install engine sump (see Workshop Manual procedure 03.02.CN Pan - Oil Sump - Remove and Reseal With
Engine Removed).
Piston-Renew (Engine Set)
Removal
1. Remove cylinder head gaskets - engine set (see Workshop Manual procedure 03.01.HW Gasket -
Cylinder Head - Engine Set - Renew With Engine
Removed).
2. Remove crankshaft timing sprocket from crankshaft.
3. Install guide pin through lower hole on chain tensioner.
4. Remove bolt securing oil pr essure pump chain tensioner
assembly to engine bedplate (see Figure 1).
Figure 1
5. Remove tensioner assembly (see Figure 2). 6. Remove bolts (x3) securing oil pressure pump to sump
(see Figure 3).
Figure 3
7. Release chain from oil pressure pump sprocket, remove oil pump.
8. Remove and discard oil pressure pump gasket.
9. Remove bolts (x3) securing oil scavenge pump to sump
(see Figure 4).
Figure 4
10. Release chain from oil scavenge pump sprocket, remove scavenge pump.
Repair Operation Time (ROT)
WA R N I N G
DO NOT GET USED ENGINE OIL ON YOUR SKIN.
USED ENGINE OIL CAN BE HARMFUL.
A0302274
A0302274A
A0302274B

Power Conversion (03.11)
Engine (03.00)3-11-8 Workshop Manual May 2007
11.Remove and discard oil scavenge pump gasket (see
Figure 5).
Figure 5
12. Remove oil pump(s) drive sprocket.
13. Disconnect multiplug from oil pressure sensor (see Figure 6).
Figure 6
14.Disconnect multiplug from engine electric coolant temperature sensor (see Figure 7).
Figure 7
15. Disconnect multiplug from cr ankshaft timing sensor (see
Figure 8).
Figure 8
A0302276
A030216
A030216A
A030206