2010 ASTON MARTIN V8 VANTAGE check engine

Engine Sealing (03.10)
Engine (03.00)
Issue 5, Janauary 2010 Workshop Manual 3-10-9
8. Install the right exhaust camshaft.
9. Install the five bearing caps in their correct positions.
10. Install the ten bolts and torque tighten them in the sequence specified.
11. Install the Torx bolt that attaches the sprocket to the camshaft.
12. Rotate the camshaft and use feeler gauges to do a check of each valve clearance .
13. Do the procedure again an d install the right intake
camshaft.
14. Remove the Torx bolt that attaches the sprocket.
15. Rotate the right intake and exhaust camshafts until the timing flats on each camshaft face up.
16. Install tool (303-530) onto the right cylinder head to hold the camshafts. Install and tighten the three bolts.
17. Install a new left cylinder he ad gasket. Make sure that it
is correctly engaged on the dowels.
18. With the aid of one more person, install the left cylinder head. Make sure that it is correctly engaged on the
dowels.
19. Install and torque the 12 cylinder head bolts in the correct sequence.
20. Lubricate the left exhaust camshaft journals, camshaft lobes, bearing surfaces on the cylinder head and the
bearing caps with clean engine oil.
21. Install left exhaust camshaft.
22. Install the five bearing caps in their correct positions.
23. Install the ten bolts and torque in the sequence specified.
24. Install the Torx bolt that attaches the sprocket to the left exhaust camshaft.
25. Rotate the left exhaust cam shaft as necessary and use
feeler guages to do a check of each valve clearance.
26. Remove the Torx bolt that attaches the sprocket.
27. Install the left intake camshaft (refer to Workshop Manual procedure 03.09.AV Camshaft - Intake - LH -
Renew).
28. Install the timing chain tensioning tool (303-532) into the right exhaust camshaft sprocket.
29. Apply a force to the tool (303-532) in a counterclockwise direction to hold the sprocket and
torque the right sprocket Torx bolts.
30. Remove the special tool.
31. Connect the electrical conne ctors to the left and right
camshaft timing sensors.
32. Connect the electrical connector to each of the two left and two right knock sensors. 33. Install SAI pump and bracket assembly (refer to
Workshop Manual procedure 03.08.DB Pump and
Bracket Assembly - Secondary Air Injection - Renew).
34. Clean the left exhaust manifold.
35. Install a new gasket for the left exhaust manifold .
36. Install the left exhaust manifold.
37. Install and torque tighten the eight nuts.
38. Install the left front wheel arch liner (refer to Workshop
Manual procedure 01.02.FB Wheel Arch Liner - Front -
LH - Renew).
39. Install the right exhaust manifold (refer to Workshop Manual procedure 09.00.CC Gasket - Exhaust Manifold
- right - Renew).
Right Side Cam Cover - Remove and
Install
Removal
1. Disconnect the battery earth cable.
2. Remove the front crush brace. (Refer to procedure
01.01.LC - Front Crush Brace)
3. Remove the right side fr ont crush bar for the body
reinforcement. (Refer to procedure 01.01.AB - Right
Side Front Crush Bar for the Body Reinforcement)
4. Remove the breather pipe from the cam cover.
5. Install applicable caps to seal the open ports.
6. Remove the ignition coil cover.
7. Disconnect the electrical connector from each of the four ignition coils.
8. Disconnect the electrical connector from the Variable Valve Timing (VVT) solenoid.
9. Release the fir tree clip that attaches the wiring harness for the ignition coils.
10. Move the wiring harness for the ignition coils away.
11. Release the wiring harness for the injectors from the mounts.
12. Cut and remove the three cable ties that attach the rear of the wiring harness for the injectors.
13. Remove the screw that attaches the purge pipe P-clip to the cam cover.
14. Move the purge-pipe P-clip away.
15. Release the purge pipe and heater pipe from the two clips on the wiring harness bracket.
16. Remove the two nuts and two screws that attach the front bracket for the wiring harness.
17. Remove the three screws that attach the rear bracket for
the wiring harness.
18. Remove the rear bracket for the wiring harness.
19. Remove the front bracket for the wiring harness.
WA R N I N G
DO NOT GET USED ENGINE OIL ON YOUR SKIN. USED ENGINE OIL CAN BE HARMFUL.
Caution
Gradually tighten one bolt and then the next to correctly
install the camshaft bearing ca ps in the step that follows.
Repair Operation Time (ROT)

Engine Sealing (03.10)
Engine (03.00)
Issue 5, Janauary 2010 Workshop Manual 3-10-13
38. Remove the four Torx bolts that attach the PAS pump mounting bracket to the cylinder block. Remove the
bracket (refer to Figure 9).
Figure 9
39. Remove the 27 bolts that attach the timing cover to the engine. Collect the bracet for the oil separator drain
tube. Remove the timing cover.
40. Remove the outer and inner rubber seals from the timing cover (refer to Figure0).
Figure0
41. Remove the front crankshaft oil seal from timing cover.
Installation
1. Clean the timing cover and mating face on engine.
2. Install the inner and outer seals into timing cover.
3. Apply 3mm x 12mm beads of sealant to the eight joints
on the engine.
4. Install the timing cover. Put the oil separator drain tube bracket in position. Install the 27 bolts and torque the
bolts in the specified sequence. 5. Using tool (303-750), instal
l front crankshaft oil seal.
Remove special tool and seal protector.
6. Clean crankshaft pulley and mating face on crankshaft.
7. Lubricate and install new O-ring seal in crankshaft pulley.
8. Install crankshaft pulley, locking ring and new pulley bolt.
9. Torque tighten crankshaft pulley bolt. Remove special tool (303-1185) from crankcase.
10. Install inspection cover to lower crankcase, install and tighten bolts (x2).
11. Install PAS pump mounting bracket, install and torque tighten Torx bolts (x4).
12. Install PAS pump, install and torque tighten bolts (x3).
13. Install alternator mounting bracket, install and torque tighten Torx bolts (x3).
14. Install alternator, install bolt and nut/bolt and torque tighten
15. Connect battery cable, install and torque tighten nut, secure cover. Connect multiplug.
16. Lubricate seal, install new oil filter.
17. Install oil separator drai n tube clip in bracket.
18. Install oil separator drain tube to timing cover.
19. Install A/C compressor idler pulley, torque tighten bolt.
20. Install alternator idler pulley, torque tighten bolt.
21. Install auxiliary drive belt te nsioner, torque tighten bolt.
22. Install water pump pulley, install bolts (x3).
23. Using a suitable socket ba r, release auxiliary drive belt
tensioner, install drive belt.
24. Torque tighten water pump pulley bolts (x3).
25. Clean coolant manifold and mating faces on cylinder heads.
26. Install new O-ring seals (x2) to coolant manifold.
27. Position coolant manifold, connect temperature sensor
multiplug, install coolant pipe in manifold.
28. Install and torque tighten Torx bolts (x4) that attach the coolant manifold to cylinder heads.
29. Connect coolant hoses (x3) to coolant manifold and
secure clips.
30. Connect engine breather to oil separator.
31. Clean left and right cam covers.
32. Install the right cam cover (Refer to ’Right Side Cam Cover - Remove and Install’, page 3-10-9).
33. Install left cam cover (Refer to ’Left Side Cam Cover -
Remove and Install’, page 3-10-4).
34. Install the engine assembly (refer to Workshop Manual procedure 03.00.AA Engine Assembly - Renew).
Caution
Make sure the cranks haft front oil seal mating faces are
clean and dry.
Caution
Do not remove the crankshaft front oil seal protector
until the oil seal is correctly installed.
If you do, the oil seal can be damaged.
A0310243
A0310245
Caution
The bolt thread in the cran kshaft must be cleaned out
before a new crankshaft pulley retaining bolt is installed.
Note: Check the crankshaft pulley and locking ring for damage.

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)3-11-4 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)3-11-6 Workshop Manual May 2007
24. Remove main bearing shells (grooved) from cylinder
block (see Figure 5).
Figure 5
25. Remove main bearing shells (plain) from engine bedplate (see Figure 6).
Figure 6
Installation
1. Clean crankshaft main bearing and connecting rod journals.
2. Clean bearing recess in cylinder block.
3. Clean old sealant from engine bedplate and bearing recesses.
4. Clean bearing shell locations in connecting rods and caps.
5. Select the correct colour coded bearing shells for each connecting rod crankshaft journal.
6. Select the correct colour coded bearing shells for each main bearing journal. 7. Install selected main bearing
shells in cylinder block and
engine bedplate.
8. Install thrust washers in cylinder block.
9. Install selected bearing shells in connecting rods and bearing caps.
10. Lubricate crankshaft journa ls with clean engine oil.
11. Position connecting rods and carefully lower crankshaft into cylinder block.
12. Install crankshaft retaining caps (303-534), install and lightly tighten bolts (x10).
13. Carefully pull each connecting rod into place on crankshaft journals.
14. Install connecting rod bearing caps (x8), install and torque tighten retaining bolts.
15. Remove bolts securing cran kshaft retaining caps (303-
534), remove retaining caps.
16. Apply a 2mm diameter continuous bead of sealant to cylinder block flange ensuring that there are no gaps in
the sealant.
17. Install engine bedplate to cylinder block, install and torque tighten bolts (x34) in the correct sequence.
18. Remove excess sealant from crankshaft rear oil seal aperture and front face of cylinder block.
19. Clean windage tray.
20. Install windage tray, install and torque tighten bolts (x8).
21. Ensure that oil seal protector is positioned correctly and install oil seal onto crankshaft flange.
22. Install tool (303-1189) to crankshaft, position nuts on tool against oil seal.
23. Ensure that oil seal and special are parallel to rear of engine.
24. To install oil seal, tighten nuts alternately on tool (303- 1189) until oil seal correctly seated.
25. Remove special tool from crankshaft.
26. Check that the oil se al is located correctly.
Note: Main bearing shells are
selective by colour code with
plain bearings in bedplate and grooved bearings in cylinder
block
Caution
Use only a plastic scraper when removing old sealant and gaskets from engine components.
A0311334
A0311335
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.
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.
Caution
Do not use any lubricant on cr ankshaft oil seals or seal
protectors. Make sure all co mponents are clean and dry.

Power Conversion (03.11)
Engine (03.00)3-11-36 Workshop Manual May 2007
4. Ensure that oil seal and special are parallel to rear of
engine.
5. To install oil seal, tighten nuts alternately on tool (303- 1189) until oil seal correctly seated.
6. Remove special tool from crankshaft.
7. Check that the oil seal is located correctly.
8. Install clutch and flywheel assembly (see Workshop Manual procedure 08.00.AA Clutch and Flywheel
Assembly - Renew).
Cylinder Block-Renew
Removal
1. Remove cylinder head gasket - engine set (see Workshop Manual procedure 03.01.HW Gasket -
Cylinder Head - Engine Set - Renew With Engine
Removed).
2. Remove crankshaft assembly.
3. Remove pistons and connecting rod assemblies from cylinder block.
4. Remove Torx screws (x4) securing engine oil cooling
valves to cylinder block.
5. Remove engine oil cooling valves (x4).
6. Remove bolts (x5) securing water pump to cylinder block. Remove water pump, discard gasket.
7. Remove cylinder block valley cover.
Installation
1. Clean cylinder block valley cover and mating face on cylinder block.
2. Install cylinder block valley cover.
3. Clean engine oil cooling valves.
4. Install engine oil cooling valves in cylinder block.
5. Install and torque tighten Torx screws (x4).
6. Clean connecting rods and piston assemblies.
7. Correctly position ring gaps on pistons prior to installation.
8. Remove connecting rod bearing caps.
9. Install bearings in connecting rods and bearing caps.
10. Lubricate cylinder bores, pistons and rings with clean engine oil.
11. Install special tools (303-535) to the connecting rod to prevent damage to crankshaft journal.
12. Install crankshaft assembly.
13. Install new gasket, water pump, install and torque tighten bolts (x5). 14. Install cylinder head gasket - engine set (see Workshop
Manual procedure 03.01.HW Gasket - Cylinder Head -
Engine Set - Renew Wi th Engine Removed).
Crankshaft Damper Pulley Assembly-
Renew (with Engine Removed)
Removal
1. Remove engine assembly (see Workshop Manual
procedure 03.00.AA Engine Assembly - Renew).
2. Release drive belt tensioner, release drive belt from idler pulley (see Figure 1).
Figure 1
3. Remove bolt securing drive belt tensioner to engine timing cover, remove tensioner.
4. Remove drive belt from pulleys.
5. Remove bolts (x2), inspection cover to lower crankcase, remove cover.
6. Install tool (303-1185) to restrain flywheel, install and tighten bolts (x2).
7. Install thrust button of tool (303 -1186) in crankshaft,
position tool in pulley, secure with bolts (x2). Tighten
centre bolt, withdraw pulley from crankshaft.
8. Collect crankshaft pulley, locking ring and special tool thrust button.
9. Remove special tool from pulley.
Caution
Alternate nut tightening to correctly seat the crankshaft rear oil seal.
Repair Operation Time (ROT)
WAR NI NG
DO NOT GET USED ENGINE OIL ON YOUR SKIN.
USED ENGINE OIL CAN BE HARMFUL.
Repair Operation Time (ROT)
ItemCode
Crankshaft Damper Pulley Assembly-
Renew 03.11.DP
A030553

Power Conversion (03.11)
Engine (03.00)3-11-38 Workshop Manual May 2007
3. Position new oil seal (fitted dry). Install oil seal in timing
cover using tool (303-750) (see Figure 3).
Figure 3
4. Remove crankshaft oil seal protector.
5. Install crankshaft pulle y (see Workshop Manual
procedure 03.11.DP Pulley Assembly - Crankshaft
Damper - Renew With Engine Removed).
Crankshaft Rear Oil Seal-Renew (with
Engine Removed
)
Removal
1. Remove engine assembly (see Workshop Manual
procedure 03.00.AA Engi ne Assembly - Renew).
2. Remove bolts (x2), inspection cover to lower crankcase, remove cover.
3. Install tool (303-1185) to restrain flywheel, install and tighten bolts (x2).
4. Remove bolts (x6), clutch cover to flywheel.
5. Release clutch cover from dowels (x3), remove clutch cover, collect drive plate.
6. Remove and discard bolts (x8), flywheel to crankshaft flange.
7. Remove bolts (x2), collect tool (303-1185).
8. Release flywheel from dowel, remove flywheel.
9. Position tool (303-1189) to crankshaft flange, screw in
alignment bolts (x2) 1.5 turns (only).
10. Use tool and pierce holes (x3) in oil seal through holes in special tool for self-tapping screws
11. Install and tighten self-tapping screws (x3) into oil seal.
12. Tighten centre bolt of tool (303-1189) and withdraw crankshaft oil seal.
13. Remove oil seal from special tool, discard oil seal.
Installation
1. Clean oil seal aperture in cylinder block.
2. Ensure that oil seal protector is positioned correctly and install oil seal onto crankshaft flange.
3. Install tool (303-1189) to crankshaft, position nuts on
tool against oil seal.
4. Ensure that oil seal and special are parallel to rear of engine.
5. To install oil seal, tighten nuts alternately on tool (303- 1189) until oil seal correctly seated.
6. Remove special tool from crankshaft.
7. Check that the oil seal is located correctly.
8. Clean flywheel and mating face on crankshaft.
9. Install flywheel, align to dowel on crankshaft flange.
10. Install new bolts (x8), install tool (303-1185) to restrain flywheel. Torque tighten bolts (x8) in the correct
sequence.
11. Clean clutch cover and drive plate.
12. Install clutch assembly on flywheel, align to dowels (x3).
13. Install bolts (x6), install clutch alignment tool, evenly torque tighten bolts (x6) in a diagonal sequence.
Remove clutch alignment tool.
14. Remove bolts (x2), collect tool (303-1185).
15. Install inspection cover, install and torque tighten bolts (x2).
16. Install engine assembly (see Workshop Manual procedure 03.00.AA Engine Assembly - Renew).
Repair Operation Time (ROT)
A0311247
Caution
Do not use any lubricant on cr ankshaft oil seals or seal
protectors. Make sure all co mponents are clean and dry
Caution
Alternate nut tightening to correctly seat the crankshaft rear oil seal.