2010 ASTON MARTIN V8 VANTAGE Workshop Manual

Power Conversion (03.11)
Engine (03.00)
May 2007 Workshop Manual 3-11-5
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 clockwis e to access number 1 cylinder
connecting rod bolts.
Remove bolts (x16) securing bearing caps to connecting rods, remove bearing caps (see Figure 2).
Figure 2
12. Install special tools (303-535) to the connecting rod to
prevent damage to crankshaft journal.
13. Carefully push each connecting rod/piston assembly up each cylinder bore.
14. Secure Dial Test Indicator (DTI) on engine bedplate.
15. Push crankshaft fully rearwards.
16. Position DTI probe on crankshaft web and zero gauge.
17. Push crankshaft fully forw ards and record reading on
dial gauge. 18. Remove DTI gauge.
19. Noting their fitted positions, remove bolts (x34) securing
engine bedplate to cylinder block (see Figure 3).
Figure 3
20. Carefully release and remove engine bedplate from cylinder block.
21. Carefully remove crankshaft from cylinder block.
22. Remove rear oil seal from crankshaft.
23. Note fitted position and remove crankshaft thrust washers (x2) from cylinder block (see Figure 4).
Figure 4
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 q
u
e tightened to yield and
mu st be replaced.
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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.
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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)
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.
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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
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Power Conversion (03.11)
Engine (03.00)
May 2007 Workshop Manual 3-11-9
16. Release harness clips (x6) from sump (see Figure 9).
Figure 9
17.Remove bolts (x4) securing LH and RH HEGO sensor
multiplug brackets to sump (see Figure 10).
Figure 10
18. Disconnect multiplug from A/C compressor.
19. Remove bolts (x4) securing A/C compressor to mounting bracket. Remove compressor.
20. Remove bolts (x2) securing inlet and outlet oil pipes to sump (see Figure 11).
Figure 11
21. Release both oil pipes together from sump, remove and discard 'O' ring seals from pipes.
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Power Conversion (03.11)
Engine (03.00)3-11-10 Workshop Manual May 2007
22. Remove Torx bolts (x4) securing A/C compressor
mounting bracket to engine bedplate and sump.
Remove bracket (see Figure 12).
Figure 12
23. Remove bolts (x16) securing sump to engine bedplate (see Figure 13).
Figure 13
24. Release and remove sump.
25. Remove bolts (x8) securing windage tray to engine bedplate, remove windage tray. 26. Mark bearing caps and connecting rods for correct
installation (see Figure 14).
Figure 14
27. Rotate crankshaft clockwise to access number 1 cylinder connecting rod bolts.
28. Remove and discard bolts (x16) securing bearing caps to connecting rods, remove bearing caps (see Figure 15).
Figure 15
29. Install special tools (303-535) to the connecting rod to prevent damage to crankshaft journal.
30. Carefully push each connecting rod/piston assembly upwards and remove from cylinder block.
31. Remove special tools from connecting rods.
32. Install bearing caps on connecting rods, install and lightly tighten retaining bolts.
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A030206D
Caution
Connecting rod bolts are tor qu
e tightened to yield and
mu st be replaced.
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Power Conversion (03.11)
Engine (03.00)
May 2007 Workshop Manual 3-11-11
33. Note that piston grade number on crown and thick
flange on connecting rod faces to front of engine on
Right Hand bank (A) (see Figure 16).
Figure 16
34. Note that piston grade number on crown and thick flange on connecting rod faces to front of engine on Left
Hand bank (B) (see Figure 17).
Figure 17
35.Remove circlip(s) securing gudgeon pin(s) in piston(s) and connecting rod(s). Remove piston(s) (see Figure 18).
Figure 18
Installation
1. Clean the cylinder bores.
2. Use an expander and remove piston rings from pistons.
3. Install piston rings, (each set), in cylinder bores to a pre-
determined depth and measure ring gaps.
4. Remove each piston ring set from cylinder bores and install on pistons
5. Clean connecting rods,
6. Install pistons on connecting rods in their correct orientation, install circlip(s).
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.
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Caution
Make sure the piston ring gaps are positioned at
different positions opposite th e thrust side of the piston
before installation.
Caution
Install pistons into cylinder block with the ‘arrow’ on the
piston crown facing to the front of the engine.
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Power Conversion (03.11)
Engine (03.00)3-11-12 Workshop Manual May 2007
12. Install piston ring clamp to each piston in turn and install
in its respective cylinder bore. Remove piston ring
clamp (see Figure 19).
Figure 19
13. Lubricate crankshaft journa ls with clean engine oil.
14. Carefully pull each connecting rod into place on each crankshaft journal.
15. Install bearing caps to their relevant connecting rods. Install and torque tighten retaining bolts (x16).
16. Clean windage tray.
17. Install windage tray, install and torque tighten bolts (x8).
18. Clean old sealant from sump flange and engine bedplate.
19. Ensure that sump flange and mating face on engine bedplate are clean and dry.
20. Apply a continuous 3mm diameter bead of RTV sealant to sump flange as recommended.
21. Ensure that there are no gaps in sealant track.
22. Install sump, install and torque tighten bolts (x16) in the correct sequence.
23. Install A/C compressor mounting bracket, install and torque tighten Torx bolts (x4).
24. Lubricate and install new O-ring seals to oil pipes.
25. Install oil pipes in sump, install and torque tighten bolts (x2)
26. Install compressor, install and torque tighten bolts (x4).
27. Connect multiplug to A/C compressor.
28. Install LH and RH HEGO sensor multiplug brackets to sump. Install and torque tighten bolts (x4).
29. Secure harness clips (x6) in sump.
30. Connect multiplug to crankshaft timing sensor.
31. Connect multiplug to engine electric coolant temperature sensor.
32. Connect multiplug to oil pressure sensor.
33. Clean oil scavenge pump and mating face on sump.
34. Install oil pump(s) drive sprocket. 35. Install new oil scavenge pump gasket, align on dowels
(x2).
36. Install chain onto oil scavenge pump sprocket.
37. Install oil scavenge pump, align to dowels (x2), Install
and torque tighten bolts (x3).
38. Install chain onto oil pump drive sprocket.
39. Clean oil pressure pump and mating face on sump.
40. Install new gasket to sump, align to dowels (x2).
41. Position oil pressure pu mp, install chain on pump
sprocket.
42. Install oil pressure pump, align to dowels (x2), Install and
torque tighten bolts (x3).
43. Install chain tensioner, install and torque tighten bolt, remove guide pin.
44. Install crankshaft timing sprocket.
45. Install cylinder head gaskets - engine set (see Workshop Manual procedure 03.01.HW Gasket - Cylinder Head -
Engine Set - Renew Wi th Engine Removed).
Piston-Renew
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 pressure pump chain tensioner assembly to engine bedplate (see Figure 1).
Figure 1
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.
A0311337
Repair Operation Time (ROT)
ItemCode
Piston-Renew 03.11.CH
WAR NI NG
DO NOT GET USED ENGINE OIL ON YOUR SKIN.
USED ENGINE OIL CAN BE HARMFUL.
A0302274