2010 ASTON MARTIN V8 VANTAGE fuel

Fuel Tank and Lines (10.01)
Fuel (10.00)10-1-6 Workshop Manual May 2007
Evaporative Loss System
Fuel vapour is displaced from the fuel tank during filling.
Vapour is also displaced due to fuel evaporation in higher
temperatures. Displaced fuel vapour is absorbed in the
carbon canister filter located on top of the fuel tank.
During normal engine running , absorbed fuel vapour is
purged from the carbon canister and mixed with the normal
fuel/air charge in the inlet manifold.
System Operation
Displaced fuel vapour leaves th e fuel tank via the normally
open fuel level vent valve and the roll over valves. It passes
through the carbon canister where fuel hydrocarbons are
absorbed. Clean air leaves the system via the normally open
canister vent valve. This valve is only closed during
diagnostic pressure testing of the fuel system.
During normal engine running, the single vapour
management valve in the engine bay is periodically opened,
when negative pressure exists in the intake manifold,
allowing fresh air flow into the open canister vent valve,
through the carbon canister, through the vapour
management valve and into the primary inlet manifold. This
fresh air flow progressively purges any absorbed fuel vapour
from the carbon canister.
Fuel Tank Vents and Control Valves
On-Board Refuelling Vapour Recovery
All of the vapour displaced from the tank by refuelling passes
through a series of valves and through a carbon canister. This
filters out and stores all the fuel vapour and clean air exits the
carbon canister port.
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Fuel Tank and Lines (10.01)
Fuel (10.00)
May 2007 Workshop Manual 10-1-7
Normal Fuel Fill - Air displaced from the fuel tank during
filling can only exit via the fuel level vent valve and roll over
valves and be forced through the carbon canister. Any fuel
vapour in the displaced air is absorbed in the carbon filter
material. No fuel vapour can escape to the atmosphere.
Clean air then exits the carbon canister, via and additional
filter, to atmosphere.
Excessive Fuel Fill - In the event of overfilling of the fuel
tank, the fuel level vent valve will close at normal maximum
fuel level. Finally the roll over vent valve will close,
completely sealing the tank. Any excess pressure in the fuel
tank will ‘blow off’ via the Ov er-pressure vent valve (part of
the roll over vent valves) in the Fuel Level vent valve
assembly.
Safety Precautions
Operations on fuel system resu lt in fuel liquid and vapour
being present in the working environment. This presents a
very serious risk and the following precautions must be
strictly observed:
Specifications
Warning
Operations on refuelling and the fuel system must only
be performed by personnel who have completed training on fuel handling.
Warning
Smoking must not be allowed near the working area. “NO SMOKING” signs must be posted around the
working area.
Warning
Any operation which could involve sparks or naked lights (e.g. battery testing, welding, metal grinding,
etc.) must not be allowed near the working area.
Warning
A CO2 fire extinguisher must be available close at hand.

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Warning
Dry sand must be available close at hand to soak up any accidental fuel spillage.
Warning
If necessary, empty the fuel into an explosion proof container using suitable fireproof fuel handling
equipment.
Warning
The working area must be well ventilated.
Warning
Disconnect the battery before commencing work on the fuel system.
Warning
Depressurise the fuel system before disconnecting any fuel lines.
Pump Pressure
Nominal pump pressure 40 psi (2.7 bar) above inlet
manifold pressure.
Torque Figures
DescriptionNmlb. / ft.
Tank retaining plate bolts 20-25 15-18.5

Fuel Tank and Lines (10.01)
Fuel (10.00)10-1-8 Workshop Manual May 2007
Maintenance
Fuel System
The fuel system must only be serviced by staff trained in fuel
handling.
Fuel Filter Assembly-Renew
Removal
1. Depressurise the fuel system (see Workshop Manual procedure 10.01.EK Fuel System - Depressurise).
2. Disconnect battery earth lead.
3. Release and remove luggage compartment rear floor carpet.
4. Remove luggage compartment front floor carpet retainers (x6).
5. Remove luggage compartment front floor carpet.
6. Remove fuel tank cover, clean off the sealant around the aperture.
7. Remove nuts (x7) and rele ase fuel tank service cover
and clamp. 8. Install the fuel tank drainage adaptor (see Fig. 1).
9. Connect the external pipe to a fuel recovery unit.
Recover the fuel in accordance with the recovery unit
instructions.
10. Release the fuel filter hoses (x2) quick release unions (see Fig. 2).
Repair Operation Time (ROT)
Warning
Read and follow all fuel handling instructions (at the beginning of the Fuel Syst em section) and the fuel
bowser manufacturers fuel handling documentation
before commencing work on the fuel system. Clean up
spillages immediately and disp ose of fuel contaminated
materials safely.
Warning
Ensure there is adequate ve ntilation inside the vehicle
(i.e. place the vehicle in a we ll ventilated area, with the
windows open).
Warning
Disconnect the battery earth lead before commencing work on the fuel system.
Caution
The following procedure is completed inside the vehicle
cabin area. Extra care must be taken to ensure no fuel or
fuel vapours come into contac t with the vehicle interior.
Fig. 1
Warning
Several litres of fuel remain in the fuel tank sump after
draining.
Fig. 2
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Fuel Tank and Lines (10.01)
Fuel (10.00)
May 2007 Workshop Manual 10-1-9
11. Remove nut fuel filter clamp to bracket (see Fig. 2).
1. Remove the fuel filter clamp and withdraw the filter.
Installation
1. Position filter in cl amp and install nut (x1).
2. Connect fuel filter hoses (x2).
3. Install fuel tank service cover (nuts x7).
4. Install fuel tank cover with new seal.
5. Install luggage compartment front floor carpet and retainers (x6)
6. install luggage compartment rear floor carpet.
7. Connect battery earth lead.
Fuel Pump and Reservoir Assembly-
Renew
Removal
1. Depressurise fuel system (see Workshop Manual procedure 10.01.EK Fuel System - Depressurise).
2. Disconnect battery earth lead.
3. Release and remove luggage compartment rear floor carpet.
4. Remove luggage compartment front floor carpet retainers (x6).
5. Remove luggage compartment front floor carpet.
6. Remove fuel tank cover, clean off the sealant around the aperture.
7. Remove nuts (x7) and release fuel tank service cover and clamp.
8. Install the fuel tank drainage adaptor (see Fig. 1).
9. Connect the external pipe to a fuel recovery unit.
Recover the fuel in accordance with the recovery unit
instructions.
Fig. 3
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)
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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
Ensure there is adequate ventilation inside the vehicle
(i.e. place the vehicle in a well ventilated area, with the
windows open).
Warning
Disconnect the battery eart h lead before commencing
work on the fuel system.
Caution
The following procedure is completed inside the vehicle
cabin area. Extra care must be taken to ensure no fuel or
fuel vapours come into contac t with the vehicle interior.
Fig. 1
Warning
Several litres of fuel remain in the fuel tank sump after draining.
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Fuel Tank and Lines (10.01)
Fuel (10.00)10-1-10 Workshop Manual May 2007
10. Remove recovery unit and fuel tank drainage adaptor.
11. Release the fuel filter hose to pump (x1) quick release
unions (see Fig. 2).
12. Release vent hose from fuel pump assembly (see Fig. 3).
13. Release fuel hose and tank harness from fuel pump bracket clip.
14. Disconnect wiring harness plugs (x2). 15. Install fuel pump removal tool (310-140) (see Fig. 4).
16. Turn the fuel pump anti-clockwise, release and
withdraw pump from mounting.
17. Remove fuel pump.
Installation
1. Position fuel pump in its mounting . Using the service tool, turn clockwise to secure fuel pump.
2. Secure fuel hose and tank harness to bracket
3. Install vent hose to fuel pump.
4. Connect hose to pump assembly.
5. Connect wiring harness multiplugs (x2).
6. Connect fuel filter pipes.
7. Install fuel tank service cover and clamp.
8. Install fuel tank cover with new seal.
9. Install luggage compartment front floor carpet and retainers (x6).
10. Install luggage compartment rear floor carpet.
11. Connect battery earth lead.
Fig. 2
Fig. 3
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Fig. 4
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 ventilat e 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.
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Fuel Tank and Lines (10.01)
Fuel (10.00)
May 2007 Workshop Manual 10-1-11
Fuel Tank and Canister Assembly-Renew
Removal
1. Disconnect vehicle battery.
2. Remove rear subframe (see Workshop Manual procedure 02.01.CA Subframe Assembly - Rear -
Remove for Access and Refit).
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 and disconnect hose from
evaporative emission contro l 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).
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 immediatel y and dispose of fuel contaminated
materials safely.
Warning
Fuel vapour is explosive. 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.
Fig. 2
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Fig. 3
Fig. 4
Fig. 5
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Fuel Tank and Lines (10.01)
Fuel (10.00)10-1-12 Workshop Manual May 2007
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
.
17. With assistance support tank, remove bolts (x14) tank to body and remove fuel tank (see Fig. 6).
18. Disconnect fuel vapour hose quick fit connection to tank (see Fig. 7). 19. Remove nut (x1) fuel tank harness earth (see Fig. 8).
20. Disconnect multiplug (x1) fuel
tank harness (see Fig. 9).
21. Release clips (x5) fuel tank harness and remove harness (see Fig. 10).
Warning
The fuel tank is heavy. Fuel tank removal / replacement is a two person operation.
Fig. 6
Fig. 7
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Fig. 8
Fig. 9
Fig. 10
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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.
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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.