2010 ASTON MARTIN V8 VANTAGE fill oil

Manual Transmission (07.03)
Transmission (07.00)7-3-8 Workshop Manual Issue 5, January 2010
32. Install the exhaust front mount.
33. Clean the component mating faces.
34. Apply an applicable sealant to the component mating faces.
35. Install the exhaust centre pipe.
36. Install and tighten the four bolts that attach the exhaust centre pipe to the exhaust front mount.
37. Put the clamps into position on the exhaust pipes.
38. Loosely install the four bolts that attach the exhaust centre pipe to the rear silencer.
39. Align the exhaust assembly.
40. Tighten the two clamps that attach the exhaust centre pipe to the catalytic converters.
41. Install the cross brace.
Figure 24
42. Install and torque the four bolts that attach the cross brace to the rear subframe.
Figure 25
43. Remove the strap that attaches the vehicle to the lift.
44. Lower the vehicle until the wheels are 10 mm above the ground. 45. Connect the battery ground cable.
46. Start the engine.
47. Select first gear and let the wheels to turn for 10
seconds.
48. Stop the engine.
49. Lift the vehicle.
50. Remove the fill plug for the transaxle oil.
51. Make sure that the transaxle oil is level with the opening for the transaxle oil. Add more oil if necessary.
52. Install and tighten the fill plug for the transaxle oil.
53. Install the rear undertray (refer to Workshop Manual
procedure 01.02.PB - Rear Undertray).
Complete Sportshift Hydraulic Kit-Renew
Removal
1. Disconnect vehicle battery.
2. Raise vehicle on ramp and secure with straps.
3. Remove road wheel(s).
4. Remove rear exhaust silencer assembly (see Workshop Manual procedure 09.00.KA Muffler & Bypass Valve
Assembly - Remove for Access & Refit).
5. Roadster Only - Remove centre undertray (see
Workshop Manual procedure 01.02.MB Undertray -
Centre - Renew).
6. Remove bolts (x4), subframe cross brace.
7. Remove centre exhaust mounting bolts (x4).
8. Loosen clamp nuts (x2), release centre pipe from both catalysts.
9. Remove centre pipe and rear exhaust pipes as an
assembly.
WAR NI NG
THE EXHAUST CENTRE PIPE IS HEAVY. GET THE AID OF ONE MORE PERSON
TO DO THE STEP THAT FOLLOWS.
WAR NI NG
TRANSAXLE OIL CAN BE HARMFUL.
OBEY ALL TRANSAXLE OIL MANUFACTURER’S SAFETY INSTRUCTIONS WHEN YO U HANDLE COMPONENTS
THAT HAVE TOUCHED TRANSAXLE OIL.
Repair Operation Time (ROT)
ItemCode
Complete Sportshift Hydraulic Kit-
Renew 07.03.AB
WAR NI NG
ALWAYS DISCONNECT THE BATTERY EARTH (- VE)
TERMINAL FIRST.
WAR NI NG
WHEN YOU LIFT THE VEHICLE ON A 'TWO POST' LIFT MAKE SURE THAT YOU USE A STRAP TO HOLD THE REAR END OF THE VEHICLE TO THE RAMP. IF YOU
DO NOT, THE VEHICLE CAN FALL OFF THE RAMP AND CAUSE PERSONAL INJURY OR DEATH.
Caution
When using a ‘two post’ vehicle ramp, remove the
screws that secure the rear section of the wheel arch
liner to body. Hold back the rear section of the wheel
arch liner to correctly position the foot of the vehicle lift.

Manual Transmission (07.03)
Transmission (07.00)
Issue 5, January 2010 Workshop Manual 7-3-31
43. Disconnect the electrical connector from the wiring
harness for the torque tube.
44. Remove the bolt that attaches the bracket for the electrical connector.
45. Move the bracket for the electrical connector away.
46. Remove the bolt that attaches the transaxle ground cable to the transaxle Automatic Shift Mechanism (ASM)
pump.
47. Disconnect the electrical connector from the ASM
pump.
48. Release the wiring harness for the ASM pump from the two clips that attach it to the transxle.
49. Identify and disconnect the five electrical connectors from the transaxle.
50. Disconnect the electrical connector from the selector
position sensor.
51. Remove the bolt that attaches the ground cable eyelet to the transaxle.
52. Put the wiring harness under the hydraulic pipe for the clutch, and move it away from the transaxle.
53. Put a transmission jack belo w the torque tube (refer to
Figure 18).
Figure 18
54. Adjust the height of the tran smission jack until it holds
the torque tube.
55. Remove the eight bolts that attach the torque tube to the transaxle.
Figure 19
56. Move the transaxle rearwards to give clearance between the torque tube and the transaxle.
57. Carefully lower the transaxle on the transmission jack to remove the transaxle from the vehicle.
Figure 20
58. Clean the mating faces of the component.
Install
1. Move the transaxle and transm ission jack into position
below the vehicle.
2. Remove the filler plug for the transaxle oil.
3. Do a level check of the transaxle oil.
4. Install and tighten the filler plug for the transaxle oil.
5. Use the transmission jack to adjust the height of the transaxle to align the transaxle with the torque tube.
6. Lower the transmission jack away from the torque tube.
7. Install and tighten the eight bolts that attach the torque tube to the transaxle.
8. Put the wiring harness for the transaxle into position.
9. Install the ground cable eyelet to the transaxle.
10. Install and tighten the bolt that attaches the ground cable eyelet to the transaxle.
11. Connect the electrical connector to the selector position sensor.
12. Connect the five electrical connectors to the transaxle.
13. Install the wiring harness for the ASM pump to the two clips that attach it to the transaxle.
14. Connect the electrical connector to the ASM pump.
15. Install the transaxle ground cable to the transaxle ASM pump.
16. Install and tighten the bolt that attaches the transaxle ground cable to the transaxle ASM pump.
17. Put the bracket for the electrical connector into position.
18. Install and tighten the bolt that attaches the bracket for the electrical connector.
WARNING
THE TRANSAXLE ASSEMBLY IS VERY HEAVY. GET THE AID OF ONE MORE PERSON WHEN YOU MOVE THE
TRANSAXLE. IF YOU DO NOT, PERSONAL INJURY CAN OCCUR.
WARNING
THE TRANSAXLE ASSEMBLY IS VERY HEAVY. GET THE AID OF ONE MORE PERSON WHEN YOU MOVE THE
TRANSAXLE. IF YOU DO NOT, PERSONAL INJURY CAN
OCCUR.

Manual Transmission (07.03)
Transmission (07.00)
Issue 5, January 2010 Workshop Manual 7-3-33
43. Install the tunnel reinforcement plate.
44. Install and torque the eight bolts that attach the tunnel reinforcement plate to the body.
45. Install floor heatshield.
46. Install and tighten the four bolts that attach the floor heat shield to the body.
47. Install the exhaust front mount.
48. Clean the component mating faces.
49. Apply an applicable sealant to the component mating faces.
50. Install the exhaust centre pipe.
51. Install and tighten the four bolts that attach the exhaust centre pipe to the exhaust front mount.
52. Put the clamps into position on the exhaust pipes.
53. Loosely install the four bolts that attach the exhaust centre pipe to the rear silencer.
54. Align the exhaust assembly.
55. Tighten the two clamps that attach the exhaust centre pipe to the catalytic converters.
56. Install the cross brace.
Figure 24
57. Install and torque the four bolts that attach the cross brace to the rear subframe.
Figure 25
58. Remove the strap that attaches the vehicle to the lift.
59. Lower the vehicle until the wheels are approximately 10 mm above the ground.
60. Connect the battery ground cable.
61. Bleed the clutch system.
62. Use AMDS to do an ASM self-tune.
63. Start the engine, select first gear and allow the wheels to turn for 10 seconds.
64. Lift the vehicle.
65. Remove the fill plug for the transaxle oil.
66. Make sure that the transaxle oil is level with the opening for the transaxle oil. Add more oil if necessary.
67. Install and tighten the fill plug for the transaxle oil.
68. Do a check of the ASM fluid level.
69. Install the rear undertray (refer to Workshop Procedure 01.02.PB - Rear Undertray)
Removal
1. Position vehicle on ramp.
2. Remove rear undertray (see Workshop Manual procedure 01.02.PB Undertray - Rear - Renew).
3. Position container to collect transaxle oil.
4. Remove transaxle drain plug and drain oil.
WA R N I N G
THE EXHAUST CENTRE PIPE IS HEAVY. GET THE AID
OF ONE MORE PERSON
TO DO THE STEP THAT FOLLOWS.
Repair Operation Time (ROT)

Manual Transmission (07.03)
Transmission (07.00)7-3-34 Workshop Manual Issue 5, January 2010
5. Loosen and disconnect oil c ooler pipes and allow oil in
the oil cooler system to drain into container.
6. Remove filler plug.
7. Discard sealing washers (x2).
Install
1. Clean drain and filler plugs.
2. Install new sealing washers to filler and drain plugs.
3. Install drain plug and tighten to correct torque.
4. Install oil cooler pipes and tighten unions to correct torque.
5. Fill transaxle with the correct grade and quantity of oil.
6. Install filler plug and tighten to the correct torque.
7. Install rear undertray (see Workshop Manual procedure 01.02.PB Undertray - Rear - Renew).
8. Lower vehicle on ramp.
9. Road test vehicle.
10. Position vehicle on ramp.
11. Check and top-up transaxle oil level.
12. Lower vehicle on ramp.
Transaxle Assembly-Renew
Removal
1. Remove transaxle assembly (see Workshop Manual procedure 07.03.AA Transaxle Assembly - Manual -
Remove for Access & Refit).
2. Attach slings to transaxle and connect suitable hoist.
3. With assistance, remove transaxle from lifter and position on work bench.
4. Lower hoist and remove slings.
5. Position container and drain transaxle oil. 6. Remove bolt securing oi
l cooler pipes bracket to
transaxle (see Figure 1).
7. Loosen and disconnect oi l cooler pipe unions and
remove oil cooler pipe assembly (see Fig 2).
WAR NI NG
OBSERVE ALL TRANSAXLE OIL MANUFACTURERS
SAFETY INSTRUCTIONS WHEN HANDLING
COMPONENTS THAT HAVE BEEN IN CONTACT WITH TRANSAXLE OIL.
WAR NI NG
OBSERVE ALL TRANSAXLE OIL MANUFACTURERS
SAFETY INSTRUCTIONS WHEN HANDLING
COMPONENTS THAT HAVE BEEN IN CONTACT WITH TRANSAXLE OIL.
WAR NI NG
OBSERVE ALL TRANSAXLE OIL MANUFACTURERS
SAFETY INSTRUCTIONS WHEN HANDLING
COMPONENTS THAT HAVE BEEN IN CONTACT WITH TRANSAXLE OIL.
Repair Operation Time (ROT)
Figure 1
WAR NI NG
OBSERVE ALL TRANSAXLE OIL MANUFACTURERS SAFETY INSTRUCTIONS WHEN HANDLING
COMPONENTS THAT HAVE BEEN IN CONTACT WITH
TRANSAXLE OIL.
Figure 2
Caution
Plug oil cooler connections to prevent ingress of dirt or
moisture into the system.

Manual Transmission (07.03)
Transmission (07.00)
Issue 5, January 2010 Workshop Manual 7-3-35
8. Remove reverse light switch from transaxle (see Fig, 3).
9. Remove bolts (x3) from selector cable bracket to transaxle and collect bracket (see Figure 4).
10. Remove nuts (x2) from select or levers (x2) to transaxle
(see Figure 5).
Install
1. Clean reverse light switch, oil cooler pipes, selector levers and selector cable bracket. 2. Install selector levers (x2) and install and torque tighten
nuts (x2).
3. Install selector cable bracket and install and torque tighten bolts (x3).
4. Install and torque tighten reverse light switch.
5. Install oil cooler pipe assembly.
6. Install and torque tighten oil cooler pipe unions and support bracket bolt.
7. Fill transaxle with the specified oil to the correct level.
8. Attach slings to transaxle and connect hoist.
9. With assistance, remove transaxle from workbench and position on lifter.
10. Install transaxle assembly (see Workshop Manual procedure 07.03.AA Transaxle Assembly - Manual -
Remove for Access & Refit).
11. Install road wheel(s).
12. Test drive vehicle.
13. Raise vehicle on ramp and check transaxle oil level.
14. Lower vehicle on ramp.
Figure 3
Figure 4
Figure 5
WA R N I N G
THE TRANSAXLE ASSEMBLY IS VERY HEAVY. TO AVOID PERSONAL INJURY OR DAMAGE TO THE TRANSAXLE, HANDLING OF THE TRANSAXLE ASSEMBLY IS A TWO
PERSON OPERATION.
WA R N I N G
THE TRANSAXLE ASSEMBLY IS VERY HEAVY. TO AVOID PERSONAL INJURY OR DAMAGE TO THE TRANSAXLE,
HANDLING OF THE TRANSAXLE ASSEMBLY IS A TWO PERSON OPERATION.
WA R N I N G
THE TRANSAXLE ASSEMBLY IS VERY HEAVY. TO AVOID
PERSONAL INJURY OR DAMAGE TO THE TRANSAXLE, HANDLING OF THE TRANSAXLE ASSEMBLY IS A TWO PERSON OPERATION.

Fuel Tank and Lines (10.01)
Fuel (10.00)
May 2007 Workshop Manual 10-1-3
Fuel Tank
The fuel tank incorporates a single filler neck and check valve, internal fuel pump, internal fuel filter, a sender unit and an
‘on board refuelling vapour recovery’ system.
Fuel Pumps

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The modular fuel pump is immersed in the base of the fuel
tank. The pump can deliver up to 150 litres/hour. The in-
tank fuel line connects to the external line using a quick-fit
connector in the base of the fuel tank. During normal running, pressu
rised fuel from each fuel
pump passes from the tank, through an 3 micron in-tank fuel
filter to one of the two fuel rails on the engine.
Fuel temperature is measured on the primary fuel rail. If fuel
temperature becomes excessive, the fuel pressure is
increased to prevent fuel vaporisation (boiling).
Fuel pressure is measured by sensors on each fuel rail. The
fuel pressure to each rail is regulated as required by
continuously changing the run speed of the associated fuel
pump. Maximum pressure in the system is limited to 5.3 bar
by in-tank pressure regulators.
A constant head of fuel is maintained in the fuel pump
modules to ensure that the pumps cannot run dry in a ‘low
fuel’ situation.

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Fuel Tank and Lines (10.01)
Fuel (10.00)
May 2007 Workshop Manual 10-1-13
22. Remove cable tie carbon canister to bracket (see Fig. 11).
23. Remove carbon canister from fuel tank (clips 4) (see Fig. 12)
24. Remove tank from support plate.
Installation
1. Position tank to support plate.
2. Install new cable tie behind carbon canister bracket.
3. Align and secure carbon canister to clips (x4).
4. Tighten cable tie around carbon canister.
5. Connect multiplug (x1) fuel tank harness.
6. Install nut (x1) fuel tank harness earth.
7. Secure fuel tank harness (clips x5).
8. Connect fuel vapour hose quick fit connection to tank.
9. With assistance position tank and secure with bolts (x14)
10. Install vacuum hose clip to tank bolts / studs (x4)
11. install vacuum hose clips to studs and secure vacuum
hose.
12. Install nuts (x5) oil cooler to body.
13. Install heatshield. 14. Connect vapour purge and fuel pipe to tank.
15. Position earth lead and secure with nut.
16. Connect fuel tank harness to main harness.
17. Connect evaporative emis
sion control assembly hose
and secure with jubilee clip.
18. install filler neck pipe and hose assembly to fuel tank.
19. Position filler neck pipe, hose assembly and sealing washer to body.
20. Install nut filler neck pipe and hose assembly to body.
21. Install bolt filler pipe brac ket to spring damper assembly.
22. install fuel filler cap
23. Install rear subframe (see Workshop Manual procedure
02.01.CA Subframe Assembly - Rear - Remove for
Access and Refit).
24. Connect vehicle battery.
Fuel Tank and Canister Assembly-
Remove for Access/Refit
Removal
1. Disconnect vehicle battery.
2. Remove rear subframe (see Workshop Manual procedure 02.01.CA Subframe Assembly - Rear -
Remove for Access and Refit).
Fig. 11
Fig. 12
Warning
The fuel tank is heavy. Fuel tank removal / replacement
is a two person operation.
$$
$%
Warning
Fire Risk. Do Not connect the vehicle battery and
switch on the ignition until all work on the fuel system
is completed and the area is cleared of fuel
contamination.
Remove contaminated material, open fuel containers
and waste fuel. Fully ventilate vehicle and work area to remove all fuel fumes.
Warning
Fire Risk. Do Not start the en gine until the fuel system
integrity is confirmed.
Repair Operation Time (ROT)
Warning
Read and follow all fuel hand ling instructions (at the
beginning of the Fuel System section) and the fuel
bowser manufacturers fuel handling documentation
before commencing work on the fuel system. Clean up
spillages immediately and dispose of fuel contaminated materials safely.
Warning
Fuel vapour is explosiv e. During the following
procedure, fuel tank and fuel lines will be open. Ensure
good ventilation and take all necessary precautions to eliminate fire risk.
Warning
Fire Risk. Before commencing work on the vehicle fuel system, disconnect the earth ( - ve) lead from the
vehicle battery.

Fuel Tank and Lines (10.01)
Fuel (10.00)10-1-14 Workshop Manual May 2007
3. Remove fuel filler cap.
4. Remove bolt filler pipe bracket to spring damper
assembly.
5. Remove nut filler neck pipe and hose to body.
6. Release filler neck pipe and hose, collect sealing washer.
7. Remove filler neck pipe and hose assembly from the
tank (using filler neck disc onnection tool - 310 - 134)
(see Fig. 2).
8. loosen jubilee clip an d disconnect hose from
evaporative emission control assembly (see Fig. 3). 9. Disconnect fuel tank harness from main harness (see
Fig. 4).
10. Remove nut and release earth lead from stud (see Fig. 5).
11. Disconnect vapour purge and fuel pipe from the tank
12. Remove bolts (x4) exhaust heatshield to floor.
13. Remove nuts (x5) oil cooler pipes to body.
14. Release exhaust vacuum pipe from clips.
15. Remove vacuum hose clips from studs.
16. Remove vacuum hose clip bolts/stud (x4) tank to body.
Fig. 2
Fig. 3
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Fig. 4
Fig. 5
Warning
The fuel tank is heavy. Fuel tank removal / replacement is a two person operation.
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