2010 ASTON MARTIN V8 VANTAGE Workshop Manual

Version 6, March 2010 Workshop Manual 6-3-1
Brake System (06.00)
Contents
Front Disc Brake (06.03)........................................ 6-3-2Description ............................................................. 3-2
Specifications.......................................................... 3-2
Maintenance ........................................................... 3-3Front Brake Disc Set - Renew ................................. 3-3
Front Caliper-Renew .............................................. 3-4
Front Pad Kit - Renew ............................................ 3-5
Front Brake Hose Assembly - Renew ...................... 3-5
Rear Disc Brakes (06.04) ....................................... 6-4-1 Description ............................................................. 4-1
Specifications.......................................................... 4-1
Maintenance ........................................................... 4-2Rear Brake Disc Set-Renew .................................... 4-2
RH/LH Rear Caliper-Renew ................................... 4-2
Rear Pad Kit-Renew ............................................... 4-3
Rear Brake Hose Assembly-Renew ......................... 4-4
Hand Brake (06.05) ................ ............................... 6-5-1
Description ............................................................. 5-1
Specifications.......................................................... 5-1
Maintenance ........................................................... 5-2 RH/LH Handbrake Caliper-Re new ......................... 5-2
Handbrake Lever Assembly-Renew ........................ 5-2
Handbrake Pad Set-Renew .................................... 5-2
Handbrake Cable Assembly-Adjust......................... 5-3
Handbrake Cable Assembly-Vehicle Set-Renew ..... 5-3
Brake Actuation System (06.06)............................. 6-6-1 Description ............................................................. 6-1
Tandem Master Cylinder ........................................ 6-1
Specifications.......................................................... 6-1
Maintenance ........................................................... 6-2Pedal Box Assembly - Renew ................................. 6-2
Installation ............................................................. 6-2
RHD-Brake Master Cylinder Assembly-Renew........ 6-2
LHD-Brake Master Cylinder Assembly-Renew ........ 6-3
Clutch Master Cylinder Assembly-Renew ............... 6-3
RH/LH Front Caliper Hose Assembly-Renew .......... 6-4
RH/LH Rear Brake Caliper Tube Assembly-Renew . 6-5
Brake Master Cylinder to Modulator Secondary
Tube Assembly-Renew ........................................... 6-6
Brake Master Cylinder to Modulator Primary
Tube Assembly-Renew ........................................... 6-7
Rear Wheel Brake Front to Rear Tube Assembly
-Renew .................................................................. 6-8
RH Front Caliper to Modulator Tube Assembly
-Renew .................................................................. 6-9
Rear Wheel Brake Tube Assembly-Renew ............ 6-10
Dynamic Stability Control Module-Renew............ 6-11
Power Brake System (06.07) .................................. 6-7-1 Brake Booster ......................................................... 7-1
Emergency Brake Assist .......................................... 7-1
Specifications.......................................................... 7-2
Maintenance ........................................................... 7-2Brake Booster-RHD-Renew.................................... 7-2
Brake Booster-LHD-Renew .................................... 7-2 Brake Fluid Reservoir-Renew ................................. 7-3
Brake Bleeding - AMDS ......................................... 7-3
Brake Master Cylinder and Vacuum Booster
-Renew .................................................................. 7-4
Brake Master Cylinder-Renew ................................ 7-5
Anti-lock Braking System (ABS) (06.09)................. 6-9-1 Dynamic Stability Control ...................................... 9-1Concept ................................................................ 9-1
System Overview ................................................... 9-2
Operation Summary .............................................. 9-2
Traction Control ..................................................... 9-2 Functional Description ........................................... 9-2
Engine Intervention ................................................ 9-3
Brake Intervention ................................................. 9-3
ABS / DSC Circuit .................................................. 9-3
Specifications ......................................................... 9-3 Maintenance ......................................................... 9-4
ABS Modulator - Remove and Install ...................... 9-4

Front Disc Brake (06.03)
Brake Systems (06.00)6-3-2 Workshop Manual Version 6, March 2010
Brake Systems (06.00)
Front Disc Brake (06.03)
Description
The front, four piston, brak e caliper is attached to the
vertical link with two bolts. The caliper is a monobloc
assembly. The steel brake discs are ventilated and grooved.
They are attached to the hub by two attachment bolts.
The two-pairs of opposed pistons operate directly on the
brake pads that are installed one each side of the disc.
Specifications
Oils/Greases
Brake Fluid Castrol Response SuperDOT 4 (Not silicon based brake fluid)
Brake pads
New pad thickness 9.4 mm
Minimum lining
thickness 2.5 mm
Torque Figures
DescriptionNm.lb. / ft.
Brake Hose Unions 22 16.5
Brake Hose Bracket to
Body 9 6.6
Brake Caliper to Vertical
Link 20 + 66°-70° 15 + 66°-70°
Handbrake Caliper to
Vertical Link 15 +90°-94° 11.5 + 90°-94°
Brake Disc Screws 10.5 8

Front Disc Brake (06.03)
Brake Systems (06.00)
Version 6, March 2010 Workshop Manual 6-3-3
Maintenance
Front Brake Disc Set - Renew
Removal
1. Raise the vehicle and make it safe.
2. Remove the road wheels.
3. Remove the pad wear sensors.
4. Remove the dust caps from the bleed nipples.
5. Install a bleed bottle.
6. Loosen the bleed nipples.
7. Push the pistons into calipers and tighten the bleed nipples.
8. Remove the bleed bottle.
9. Install the dust caps on the bleed screws.
10. Remove the brake pad retaining pins and anti-rattle springs.
11. Remove the two caliper attachment bolts from each caliper.
12. Use a cable tie to hold each caliper away.
13. Remove the two disc attachment screws and the two discs.
Installation
1. Clean the two hubs. 2. Install the two discs.
3. Install and torque two attachment screws into each disc.
4. Put each caliper in position and attach it with two new
bolts.
5. Torque the caliper attachment bolts.
6. Clean the calipers, pins, shims and springs.
7. Apply anti-seize compound to the pads, pins and shims.
8. Install the pads and shims into the caliper.
9. Install the pad retaining pins and springs into the calipers.
10. Install the pad wear sensors.
11. Operate the brake pedal four times.
12. Fill the brake fluid reservoir to the correct level.
13. Install the road wheels.
14. Lower the vehicle.
Repair Operation Time (ROT)
WAR NI NG
ALWAYS INSTALL NEW BOLTS WHEN YOU INSTALL THE BRAKE CALIPER. IF YOU DO NOT THE BOLTS
CAN BREAK AND CAUSE FAILURE OF THE BRAKE.
When you install new brake pads, install a new brake pad wear sensor.
WA R N I N G
BEFORE YOU DRIVE THE VEHICLE, OPERATE THE
FOOT BRAKE PEDAL 2 OR 3 TIMES TO MAKE SURE
THAT THE FOOT BRAKE OPERATES CORRECTLY. YOU MUST OPERATE BRAKE CALIPER PISTONS TO CLOSE THE SPACE BETWEEN THE BRAKE PADS AND THE
DISC.

Front Disc Brake (06.03)
Brake Systems (06.00)6-3-4 Workshop Manual Version 6, March 2010
Front Caliper-Renew
Removal
1. Raise the vehicle and make it safe.
2. Remove the road wheel.
3. Remove the pad wear sensor.
4. Move the caliper pistons into to the caliper to release the pads.
5. Remove the brake pad retaining pins and anti-rattle spring.
6. Remove the pads and shims from the caliper.
7. Disconnect the brake hose.
8. Install sealing plugs into the open brake-pipe port of the caliper and the hose to prevent contamination.
9. Remove and discard the two caliper attachment bolts.
10. Remove the caliper.
Installation
1. Clean the pads, pins, shims and the spring .
2. Install a new caliper and attach it with two new bolts.
3. Torque the two caliper attachment bolts.
4. Apply anti-seize compound to the pads, pins and shims.
5. Install the pads and shims into the caliper.
6. Install the pad retaining pins and spring into the caliper.
7. Remove the sealing plug from the brake-pipe port.
7.1 Loosely install the brake hose union into the caliper.
7.2 Make sure that the brake hose alignment line is straight. Adjust the hose if necessary.
7.3 Install the alignment tool (206-100).
7.4 Use the tool to align the hose and tighten the union to 22 Nm .
7.5 Do a check of the hose alignment again. If the hose is not correctly aligned, loosen the union and adjust
the hose. Tighten the union to 22 Nm.
8. Install the pad wear sensor.
9. Remove the dust cap from the bleed nipple.
10. Install the bleed bottle.
11. Fill the brake fluid reservoir to the correct level.
12. With the aid of one more person, bleed the brake caliper.
13. Remove the bleed bottle.
Repair Operation Time (ROT)WAR NI NG
DO NOT USE COMPRESSED AIR TO REMOVE BRAKE
PAD DUST. THE DUST CAN BE DANGEROUS. ALWAYS USE A VACUUM BRUSH OR THE RECOMMENDED BRAKE CLEANER TO REMOVE BRAKE PAD DUST.
WA R N I N G
ALWAYS INSTALL NEW BOLTS WHEN YOU INSTALL THE BRAKE CALIPER. IF YOU DO NOT THE BOLTS
CAN BREAK AND CAUSE FAILURE OF THE BRAKE.
When you install new brake pads, install a new brake pad wear sensor.
CAUTION
MAKE SURE THAT THE ALIGNMENT LINE ON THE BRAKE HOSE STAYS IN A STRAIGHT LINE. IF THE
ALIGNMENT LINE IS NOT STRAIGHT, THE BRAKE HOSE IS TWISTED. THIS CAN CAUSE IT TO FAIL.
CAUTION
ON LEFT AND RIGHT CALIPERS, THE BRAKE HOSE MUST GO TOWARDS THE FRONT OF THE CAR.

Front Disc Brake (06.03)
Brake Systems (06.00)
Version 6, March 2010 Workshop Manual 6-3-5
14. Install the dust cap for the bleed nipple.
15. Fill the brake fluid reservoir to the correct level.
16. Install road wheel.
17. Lower the vehicle.
Front Pad Kit - Renew
Removal
1. Raise the vehicle and make it safe.
2. Remove the road wheels.
3. Remove the pad wear sensors.
4. Remove the dust caps from the bleed nipples .
5. Install a bleed bottle onto each bleed nipple.
6. Loosen the bleed nipples and push pistons into calipers.
7. Tighten bleed nipples.
8. Remove the bleed bottles.
9. Install the dust caps onto the bleed nipples.
10. Remove the brake pad retaining pins and anti-rattle springs.
11. Remove the pads and shims from the calipers.
Installation
1. Clean the calipers, pins, shims and the springs.
2. Apply anti-seize compound to the pads, pins and shims.
3. Install the pads and shims into the caliper.
4. Install the pad retaining pins and springs into the calipers.
5. Install the pad wear sensors.
6. Operate the brake pedal four times.
7. Fill the brake fluid reservoir to the correct level.
8. Install the road wheels.
9. Lower the vehicle.
Front Brake Hose Assembly - Renew
Removal
1. Raise the vehicle and make it safe.
2. Remove the applicable road wheel.
3. Remove the dust cap from the bleed nipple.
4. Install a bleed bottle onto the applicable caliper.
5. Open the bleed nipple.
6. Push the brake pedal approximately 60 mm and hold it with a support.
7. Tighten the bleed nipple.
8. Remove the bleed bottle.
9. Install the dust cap on the bleed nipple.
10. Disconnect the brake hose union from the caliper.
11. Install sealing plugs in the open ports.
12. Remove the brake pipe union from the hose.
13. Remove the M6 screw that attaches the hose bracket to the body.
14. Remove the hose.
Installation
1. Put the hose in position.
2. Install and torque the M6 screw that attaches the hose bracket to the body.
3. Install and torque the brake pipe union onto the hose.
WA R N I N G
BEFORE YOU DRIVE THE VEHICLE, OPERATE THE
FOOT BRAKE PEDAL 2 OR 3 TIMES TO MAKE SURE
THAT THE FOOT BRAKE OPERATES CORRECTLY. YOU MUST OPERATE BRAKE CALIPER PISTONS TO CLOSE
THE SPACE BETWEEN THE BRAKE PADS AND THE DISC.
Repair Operation Time (ROT)
WA R N I N G
DO NOT USE COMPRESSED AIR TO REMOVE BRAKE
PAD DUST. THE DUST CAN BE DANGEROUS. ALWAYS USE A VACUUM BRUSH OR THE RECOMMENDED BRAKE CLEANER TO REMOVE BRAKE PAD DUST.
When you install new brake pads, install a new brake pad wear sensor.
Repair Operation Time (ROT)

Front Disc Brake (06.03)
Brake Systems (06.00)6-3-6 Workshop Manual Version 6, March 2010
4. Remove the sealing plugs from the port in the caliper and the hose.
4.1 Loosely install the brake hose union into the caliper.
4.2 Make sure that the brake hose alignment line is straight. Adjust the hose if necessary.
4.3 Install the alignment tool (206-100).
4.4 Use the tool to align the hose and tighten the union to 22 Nm .
4.5 Do a check of the hose alignment again. If the hose is not correctly aligned, loosen the union and adjust
the hose. Tighten the union to 22 Nm.
5. Remove the pedal support.
6. Fill the brake fluid reservoir to the correct level.
7. Get the aid of one more person and bleed the brake caliper.
8. Remove the bleed bottle.
9. Install the bleed nipple dust cap.
10. Clean all spilled brake fluid.
11. Fill the brake fluid reservoir to the correct level.
12. Install the road wheel.
13. Lower the vehicle. CAUTION
MAKE SURE THAT THE ALIGNMENT LINE ON THE BRAKE HOSE STAYS IN A STRAIGHT LINE. IF THE
ALIGNMENT LINE IS NOT STRAIGHT, THE BRAKE
HOSE IS TWISTED. THIS CAN CAUSE IT TO FAIL.
CAUTION
ON LEFT AND RIGHT CALIPERS, THE BRAKE HOSE MUST GO TOWARDS THE FRONT OF THE CAR.

Rear Disc Brakes (06.04)
Brake system (06.00)
May 2007 Workshop Manual 6-4-1
Brake system (06.00)
Rear Disc Brakes (06.04)
Description
The rear, four piston, brake caliper is bolted directly to the ve rtical link by two bolts. The caliper is a monobloc assembly.
The steel brake discs are ventilated and grooved. Th ey are secured to the hub by two retaining bolts.
Specifications
06-04-001Caliper BoltRear Caliper
Brake Hose Assy
Brake Pad Kit
Brake Pad Sensor Assy
Rear Brake Disc ShieldGrooved Brake Disc
Oils/Greases
Brake Fluid Castrol Response Super DOT 4 (Not
silicon based brake fluid)
Brake pads
Minimum lining thickness 2.5
Torque Figures
DescriptionNm.lb. / ft.
Brake hose unions 22 16.5
Service brake Caliper to
Vertical Link 20 + 66°-70° 15 + 66°-70°
Handbrake Caliper to
Vertical Link 15 + 90°-94° 11.5 + 90°-94°

Rear Disc Brakes (06.04)
Brake system (06.00)6-4-2 Workshop Manual May 2007
Maintenance
Rear Brake Disc Set-Renew
Removal
1. Raise vehicle on ramp.
2. Remove road wheel/s
3. Remove pad wear sensors.
4. Remove bleed nipple dust caps.
5. Fit bleed bottle.
6. Loosen bleed nipples, push pistons into Calipers, tighten bleed nipples.
7. Remove bleed bottle.
8. Fit bleed screw dust caps.
9. Remove brake pad retaining pins and anti-rattle springs.
10. Remove Caliper bolts (x4) and tie Caliper aside.
11. Remove handbrake Caliper bolts (x4) and tie Calipers aside.
12. Remove retaining screws (x4) and discs.
Installation
1. Clean hubs.
2. Install discs and retaining screws.
3. Install Calipers and retaining bolts.
4. Install handbrake Ca lipers (bolts x4).
5. Clean components (Caliper s, pins, shims, springs)6. Apply anti-seize compound to pads, pins and shims.
7. Install pads and shims to Caliper.
8. Install retaining pad pins
and springs to Calipers.
9. Install pad wear sensors.
10. Pump brake pedal.
11. Top-up brake fluid.
12. Install road wheel/s
13. Lower vehicle on ramp.
RH/LH Rear Caliper-Renew
Removal
1. Raise vehicle on ramp.
2. Remove road wheel/s
3. Remove pad wear sensor.
4. Ease Caliper pistons to release pads.
5. Remove brake pad retaining pins and anti-rattle spring.
6. Remove pads and shims from Caliper.
7. Remove brake hose (cap and plug open orifices).
8. Remove Caliper bolts (x2) and Caliper.
Repair Operation Time (ROT)
When installing new brake pads, install a new brake pad wear sensor.
WAR NI NG
BEFORE MOVING OFF, PUMP THE FOOT BRAKE 2 OR
3 TIMES TO ENSURE THE FOOT BRAKE WORKS
CORRECTLY. BRAKE CALIPER PISTONS MAY REQUIRE TRAVEL TO CONTACT THE BRAKE PADS AND DISC.
Repair Operation Time (ROT)
ItemCode
Rear Caliper-Renew RH06.04.AB
Rear Caliper-Renew LH06.04.AC
WAR NI NG
AVOID SKIN / EYE CONTACT OR INGESTION OF
BRAKE FLUID. IF SKIN OR EYES ARE SPLASHED WITH BRAKE FLUID, RINSE THE AFFECTED AREA
IMMEDIATELY WITH PLENTY OF WATER AND OBTAIN
MEDICAL ATTENTION. IF BR AKE FLUID IS INGESTED,
OBTAIN IMMEDIATE MEDICAL ATTENTION.
WAR NI NG
BRAKE FLUID IS HYGROSCOPIC. IF KEPT IN OPENED CONTAINERS IT WILL ABSORB WATER VAPOUR. USE ONLY BRAKE FLUID FROM FRESHLY OPENED
CONTAINER.
Caution
Brake fluid must not be allowed to contact the vehicle
paint work. Remove spilt brake fluid from the paint work
by rinsing away with running water.
Place an absorbent cloth around the brake fluid reservoir filler neck to absorb any possible brake fluid spillage.