2010 ASTON MARTIN V8 VANTAGE Workshop Manual

Engine Sealing (03.10)
Engine (03.00)
Issue 5, Janauary 2010 Workshop Manual 3-10-3
46. Remove the four M8 Torx bolts that attach the PAS pump mounting bracket to the cylinder block and
remove the bracket (refer to Figure 6).
Figure 6
47. Remove the 27 M6 bolts that attach the timing cover to the engine.
48. Collect the bracket for the oil separator drain tube.
49. Remove the timing cover.
50. Remove the outer and inner rubber seals from timing cover (Refer to Figure 7).
Figure 7
51. Remove the front crankshaft oil seal from the timing
cover.
Install
1. Examine the condition of the seal in the John Guest cartridge connector for the oil return pipe. If there are
signs that the connector has leaked, install a new John
Guest cartridge kit (Refer to ’John Guest Cartridge in the
Engine Timing Cover - Repair’, page 3-10-14).
2. Clean the timing cover and the mating face on the engine. 3. Install the inner and outer seals to the timing cover.
4. Apply 3mm x 12mm beads of sealant to the eight joints
on the engine.
5. Install the timing cover. Put the oil separator drain tube bracket in position and install the 27 M6 bolts..
6. Torque the 27 bolts in the sequence shown in Figure 8.
Figure 8
7. Use tool (303-750) to install the front crankshaft oil seal.
8. Remove the special tool and the seal protector.
9. Use an M16 x 2 plug tap to clean the thread in the crankshaft.
10. Clean the crankshaft pulley and mating face on the crankshaft.
11. Lubricate and install a new O-ring seal in the crankshaft pulley.
12. Examine the crankshaft pulley and the taper collet for damage. Replace all damaged parts.
13. Install the crankshaft pulley, taper collet and a new pulley bolt.
14. Torque tighten the crankshaft pulley bolt.
15. Remove the special tool (303-1185) from the crankcase.
16. Install the inspection cover to the lower crankcase, install and tighten the two attachment bolts.
17. Install the PAS pump mounting bracket. install and torque tighten the four M8 Torx bolts.
18. Install the PAS pump. Install and torque the three M8 bolts.
19. Install the alternator mounting bracket. Install and torque tighten the three M8 Torx bolts.
WA R N I N G
DO NOT GET USED ENGINE OIL ON YOUR SKIN.
USED ENGINE OIL CAN BE HARMFUL.
Caution
Make sure the cranks haft front oil seal mating faces are
clean and dry.
A0310243
A0310245
Caution
Do not remove the crankshaft front oil seal protector
until the oil seal is correctly installed.
Caution
Clean the thread in the cran kshaft before you install a
new crankshaft pulley bolt. If you do not you can not apply the correct torque to the bolt.

Engine Sealing (03.10)
Engine (03.00)3-10-4 Workshop Manual Issue 5, Janauary 2010
20. Put the alternator in position.
21. Install the M8 bolt that attaches the top of the alternator.
22. Install the M10 nut and bolt that attaches the bottom of the alternator.
23. Torque tighten the alternator attachment bolts.
24. Connect the battery cable to the alternator.
25. Install and torque the nut that attaches the battery cable.
26. Install the cover for the cable connection.
27. Connect the electrical connector to the alternator.
28. Apply new engine oil to the seal on a new oil filter.
29. Install the new oil filter.
30. Install the drain tube for the oil separator into the clip in the bracket.
31. Install the drain tube for the oil separator into timing cover.
32. Install the idler pulley for the air conditioning compressor.
33. Install and torque the M10 bolt that attaches the idler pulley.
34. Install the alternator idler pulley.
35. Install and torque the M10 bolt that attaches the idler pulley.
36. Install the auxiliary drive belt tensioner.
37. Install and torque the M10 bolt that attaches the tensioner.
38. Put the water pump pulley in position.
39. Install the three M6 bolts that attach the water pump pulley.
40. Turn the auxiliary drive be lt tensioner until you can
install the drive belt.
41. Torque tighten the three M6 water pump pulley bolts.
42. Clean the coolant manifold and the mating faces on the cylinder heads.
43. Install two new O-ring seals into the coolant manifold.
44. Put the coolant manifold in position.
45. Connect the electrical connector for the temperature sensor.
46. Install the coolant pipe in the manifold.
47. Install and torque tighten the four M6 Torx bolts that attach the coolant manifold to the cylinder heads.
48. Connect the three coolant hoses to the coolant manifold and install the hose clips.
49. Connect the engine breather to the oil separator.
50. Clean the left and right cam covers.
51. Install the inner and outer seals on the left cam cover.
52. Install the left cam cover (Refer to ’Left Side Cam Cover - Remove and Install’, page 3-10-4).
53. Install the inner and outer seals on the right cam cover.
54. Install the right cam cover (Refer to ’Right Side Cam Cover - Remove and Install’, page 3-10-9).
55. Install the front subframe (refer to Workshop Manual procedure 02.01.BA Subframe Assembly - Front -
Remove for Access and Refit). 56. Install the oil tank assembly
(refer to Workshop Manual
procedure 03.02.CA Tank Assembly - Oil Cooler -
Renew).
57. Fill the cooling system (refer to Workshop Manual procedure 03.03.AD Coolant - Drain and Refill).
Left 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 left side front crush bar for the body reinforcement. (Refer to procedure 01.01.AC - Left Side
Front Crush Bar for the Body Reinforcement).
4. Disconnect the breather pi pes from the cam cover and
the oil tank Y-piece.
5. Use 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. Release the purge pipe an d heater pipe from the two
clips on the wiring harness bracket.
14. Remove the two nuts and three screws that attach the front bracket for the wiring harness.
15. Remove the three screws that attach the rear bracket for the wiring harness.
16. Cut and remove the four cable ties that attach the rear
of the wiring harness to the front bracket.
17. Remove the rear bracket for the wiring harness.
18. Remove the front bracket for the wiring harness.
19. Remove the screw that attaches each of the four ignition coils.
20. Remove the four ignition coils.
21. Remove the 14 screws that attach the cam cover to the
engine.
Repair Operation Time (ROT)
ItemCode
Left Side Cam Cover - Remove and
Install 03.10.AS
Note: When you remo ve the cam cover attachment bolts in
the step that follows , record their installed positions in the
cam cover.

Engine Sealing (03.10)
Engine (03.00)
Issue 5, Janauary 2010 Workshop Manual 3-10-5
22. Remove and discard the seals for the 14 cam cover screws.
23. Remove the cam cover.
24. Remove the breather pipe stub.
25. Remove and discard the seal for the breather pipe stub.
26. Remove and discard the O-ring seal for the VVT
solenoid.
27. Remove and discard the cam cover gasket.
28. Remove and discard the four O-ring seals from the spark plug wells.
29. 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. Install a new seal for the breather pipe stub.
5. Install the breather pipe stub.
6. Apply a 6 mm diameter sphere of silicon RTV sealant at the positions shown in Figure C03-10-102.
Figure C03-10-102
7. Install the cam cover.
8. Install new seals for the 14 cam cover screws.
9. Install and torque the 14 screws that attach the cam cover to the engine in the sequence shown to 10 Nm.
Figure C03-10-051
10. Install the four ignition coils. 11. Install and torque the screw that attaches each of the
four ignition coils to 5 Nm.
12. Install the front bracket for the wiring harness.
13. Install the rear bracket for the wiring harness.
14. Install and torque the three screws that attach the rear bracket for the wiring harness to 11 Nm.
15. Install and tighten the two nuts and three bolts that attach the front bracket for the wiring harness.
16. Install the purge pipe and he ater pipe into the two clips
on the wiring harness bracket.
17. Use four 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 connector 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. Connect the breather pipes to the cam cover and the oil tank Y-piece.
25. Install the left side front crush bar for the body reinforcement. (Refer to procedure 01.01.AC - Left Side
Front Crush Bar for the Body Reinforcement).
26. Install the front crush brace. (Refer to procedure 01.01.LC - Front Crush Brace).
27. Connect the battery earth cable
Left Side Cam Cover Gasket - Renew
Removal
1. Remove the left cam cover (Refer to ’Left Side Cam Cover - Remove and Install’, page 3-10-4).
2. Remove and discard the cam cover gasket.
Installation
1. Clean the mating faces of the cam cover and the cylinder head.
2. Put the new cam cover gasket in position.
3. Install the left cam cover (Refer to ’Left Side Cam Cover - Remove and Install’, page 3-10-4).
CAUTION
Tighten the screws gradually and equally in the step
that follows. If you do not, the cam cover gasket can be
damaged.
C03-10-102
CAUTION
M a k e s u re th a t th e ve h i c le i s o n i t s r o a d w h e el s on l ev e l
ground when you do the do the steps that folllow. If you
do not, the front of the vehicle can be twisted when the cross brace is tightened.
Repair Operation Time (ROT)

Engine Sealing (03.10)
Engine (03.00)3-10-6 Workshop Manual Issue 5, Janauary 2010
Right Side Cam Cover Gasket - Renew
1. Remove the right cam cover (Refer to ’Right Side Cam Cover - Remove and Install’, page 3-10-9).
2. Remove and discard the cam cover gasket.
Installation
1. Clean the mating faces of the cam cover and the cylinder head.
2. Put the new cam cover gasket in position.
3. Install the right cam cover (Refer to ’Right Side Cam
Cover - Remove and Install’, page 3-10-9).
Cylinder Head Gasket - Renew (Engine
Set)
Removal
1. Remove the SAI pump and bracket assembly (refer to procedure 03.08.DB Pump and Bracket Assembly -
Secondary Air Injection - Renew).
2. Disconnect the electrical connector from each of the two left and two right knock sensors.
3. Disconnect the electrical connector from the left and right camshaft timing sensors.
4. Remove the right exhaust manifold (refer to procedure 09.00.CC Gasket - Exhaust Manifold - RH - Renew).
5. Remove the left front wheel arch liner (refer to procedure 01.02.FB Wheel Arch Liner - Front - LH -
Renew).
6. Remove the eight nuts that attach the left exhaust manifold to cylinder head.
7. Remove the left exhaust ma nifold. Remove and discard
the gasket.
8. Remove the left intake camshaft (refer to Workshop Manual procedure 03.09.AV Camshaft - Intake - LH -
Renew). 9. Remove the 10 left exhaust camshaft bearing cap
attachment bolts evenly and in steps (refer to Figure 1).
Figure 1
10. Record the positions and the markings of the bearing caps for the left exhaust camshaft .
11. Remove the bearing caps for the left exhaust camshaft.
Figure 2
12. Remove the two bolts that attach the front end of the left cylinder head to the cylinder block.
Repair Operation Time (ROT)
Repair Operation Time (ROT)
A0309270
A0309272

Engine Sealing (03.10)
Engine (03.00)
Issue 5, Janauary 2010 Workshop Manual 3-10-7
13. Remove the 10 bolts evenly and in steps, that attach the left cylinder head to the cylinder block (refer to Figure
3).
Figure 3
14. With the aid of one more person, remove the left cylinder head assembly.
15. Remove and discard the cylinder head gasket.
16. Remove the two Torx bolts, the spacer on the exhaust and the Torx bolt that attaches the right intake and
exhaust camshaft sprockets to the camshafts (refer to
Figure 4).
Figure 4
17. Remove the two bolts that attach the right secondary timing chain tensioner to the cylinder head (refer to
Figure 5).
Figure 5
18. Remove the right camshaft sp rockets complete with the
timing chain and tensioner from the camshafts (refer to
Figure 6).
Figure 6
19. Remove the three bolts that attach tool (303-530) to the cylinder head. Remove the special tool (refer to Figure
7).
Figure 7
A0310319
A0309252
A0309253
A0309254
A0309271

Engine Sealing (03.10)
Engine (03.00)3-10-8 Workshop Manual Issue 5, Janauary 2010
20. Remove the ten bolts evenly and in steps, that attach the bearing caps for the right intake camshaft (refer to
Figure 8).
Figure 8
21. Record the positions and the markings of the bearing caps for the right intake camshaft.
22. Remove the right intake camshaft (refer to Figure 9).
Figure 9
23. Remove the ten bolts evenly and in steps, that attach the bearing caps for the right exhaust camshaft (refer to
Figure 10).
Figure 10
24. Record the positions and the markings of the bearing caps for the right exhaust camshaft.
25. Remove right exhaust camshaft (refer to Figure 11).
Figure 11
26. Remove the two bolts that attach the front end of the right cylinder head to the cylinder block.
27. Remove the ten bolts evenly and in steps, that attach the right cylinder head to the cylinder block (refer to
Figure 12).
Figure 12
28. With the aid of one more person, remove the right cylinder head assembly.
29. Remove and discard the cylinder head gasket.
Installation
1. Fully clean the left and right cylinder head faces and the attachment bolt pockets.
2. Fully clean the left and right cylinder block faces.
3. Fully clean and dry the left and right cylinder head retaining bolts.
4. Install a new right cylinder gasket. Make sure that it is correctly engaged on the dowels.
5. With assistance, install the right cylinder head. Make sure it is correctly engaged on the dowels.
6. Install and torque tighten the 12 cylinder head bolts in the correct sequence.
7. Lubricate the camshaft journals, camshaft lobes, bearing surfaces on cylinder head and the bearing caps with
clean engine oil.
A0309258
A0309259
A0309258
A0309260
A0310319

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)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