2010 ASTON MARTIN V8 VANTAGE Workshop Manual

May 2007 Workshop Manual 8-1-1
Clutch (08.00)
Contents
Clutch Assembly (08.01)........................................ 8-1-2Description ............................................................. 1-2
Specifications.......................................................... 1-2
Maintenance ........................................................... 1-2 Clutch and Flywheel Assembly-Renew ................... 1-2
Slave Clutch Cylinder-Renew ................................. 1-3
Clutch Bleed Hose Assembly-Renew ...................... 1-4
Clutch Hydraulic System-Bleed-Sportshift Only ...... 1-4
Clutch Hydraulic System-Bleed .............................. 1-5
Master Cylinder to Slave Cylinder Tube
Assembly-Renew-Sportshift Only............................ 1-5

Clutch Assembly (08.01)
8-1-2 Workshop Manual May 2007
Clutch (08.00)
Clutch Assembly (08.01)
Description
The clutch assembly consists of a balanced flywheel, a clutch
driven plate and a clutch cover.
The clutch is a single plate, diaphragm spring type assembly.
A concentric clutch slave cylinder is mounted around the
first motion shaft in the torque tube bell housing.
The clutch master cylinder is mounted on the engine
bulkhead and is operated directly by the clutch pedal.
A hydraulic connection from the master cylinder feeds
pressurised fluid to the slave cylinder. The slave cylinder has
an extension tube and bleed nipple extending from the left
side of the bell housing for bleeding the system after any
major work.
Specifications
Maintenance
Clutch and Flywheel Assembly-Renew
08.00.AA
Removal
1. Disconnect vehicle battery.
2. Raise vehicle on ramp.
3. Remove torque tube assembly (see Workshop Manual procedure 05.01.CA Torque Tube Remove for Access
and Refit).
4. Remove bolts (x2) from inspection cover to lower crankcase and remove cover. 5. Install special tool SKAM14546 OT to restrain flywheel
and install and tighten bolts (x2) (see Fig. 1).
6. Remove bolts (x6) from clutch cover to flywheel (see Fig.
2).
7. Release clutch cover from dowels, remove cover and collect drive plate.
Clutch Fluid
Castrol/Girling Universal Brake and Clutch fluid.
Clutch Assembly
Clutch and flywheel are separately balanced.
Clutch Plate
Single 267mm driven plate.
Torque Figures
DescriptionNmlb/ft
Flywheel Bolts
Tighten the bolts in sequence. Loosen
the bolts and then torque, in even
stages, in the same sequence. 100 -
120
74-
88.5
Clutch Bolts
Tighten x6 equally-spaced bolts, in-
turn, to pull-down the clutch evenly.
Then torque all bolts in sequence. 65-75 48-55
Starter Motor Bolts 42.5-
57.531.5-
42.5
Repair Operation Time (ROT)
Fig. 1
Fig. 2
Warning
The clutch assembly is heavy. Ensure the clutch
assembly is supported befo re removing final bolts.



Clutch Assembly (08.01)
May 2007 Workshop Manual 8-1-3
8. Remove bolts (x8) from flywheel to crankshaft and discard bolts (see Fig. 3).
9. Remove bolts (x2) and collect special tool SKAM14546 OTC.
10. Release flywheel from dowels and remove flywheel.
Installation
1. Clean flywheel and mating face on crankshaft flange.
2. Inspect pilot bearing for wear.
3. Position flywheel and align to dowel(s) on crankshaft flange.
4. Install bolts (x8) and install special tool SKAM14546 OTC to restrain flywheel.
5. Tighten flywheel bolts in the correct sequence.
6. Clean clutch cover and drive plate.
7. Install clutch assembly on flywheel and align to dowels.
8. Install bolts (x8), insert clutch alignment tool and evenly tighten bolts to the correct torque.
9. Remove clutch alignment tool.
10. Remove bolts (x2) and collect tool.
11. Install inspection cover to crankcase and tighten bolts (x2).
12. Install torque tube assembly (see Workshop Manual procedure 05.01.CA Torque Tube Remove for Access
and Refit).
13. Lower vehicle on ramp.
14. Connect vehicle battery.
Slave Clutch Cylinder-Renew
08.00.AC
Removal
1. Disconnect vehicle battery.
2. Raise vehicle on ramp.
3. Remove torque tube (see Workshop Manual procedure 05.01.CA Torque Tube Remove for Access and Refit).
4. Release clips and remove bleed and supply pipes from slave cylinder.
5. Install clips in union
6. Loosen and remove pipe adaptors (x2) from slave cylinder (see Fig. 1).
7. Sportshift Only - Remove bolts (x2) securing clutch
position sensor to slave cylinder.
Fig. 3
Warning
The flywheel is heavy. Ensure the flywheel is supported
before removing.
Warning
The flywheel is heavy. Ensure the flywheel is supported
when installing.
Warning
The clutch assembly is heavy. Ensure the clutch
assembly is supporte d when installing.
Caution
The flywheel and pressure are a balanced assembly. Ensure alignment marks are aligned.

Repair Operation Time (ROT)
Warning
Always disconnect the battery earth (- ve) terminal first.
Warning
When raising the vehicle on a ‘two post’ ramp, ensure
that the rear end of the vehicle is securely strapped to
the ramp. Failure to strap the rear of the vehicle down may lead to the vehicl e falling off the ramp.
Caution
Always plug pipe ends to prevent ingress of dirt or moisture into the system.
Fig. 1


Clutch Assembly (08.01)
8-1-4 Workshop Manual May 2007
8. Remove bolts (x2) that secure slave cylinder to torque tube (see Fig. 2).
9. Remove slave cylinder and collect spacer.
Installation
1. Clean slave cylinder, spacer and pipe adaptors.
2. Install spacer and slave cylinder and tighten bolts (x2).
3. Sportshift Only - Install clutch position sensor to slave
cylinder and secure with bolts.
4. Install pipe adaptors (x2) in slave cylinder.
5. Install bleed and supply pipes onto slave cylinder adaptors (x2) and secure with clips.
6. Install torque tube (see Workshop Manual procedure 05.01.CA Torque Tube Remove for Access and Refit).
7. Bleed clutch (see Workshop Manual procedure 08.00.AF Clutch Hydraulic System - Bleed).
8. Lower vehicle on ramp.
9. Connect vehicle battery.
Clutch Bleed Hose Assembly-Renew
08.00.AD
Removal
1. Raise vehicle on ramp.
2. Coupe Only - Remove deflector - front floor heatshield
(see Workshop Manual proc edure 09.04.AA Heatshield
- Front Floor - Renew).
3. Roadster Only - Remove exhaust sysytem (see
Workshop Manual procedure 09.00.NB Exhaust System
- Excluding manifold/down pipes - Renew). 4.
Roadster Only - Remove grommet sealing clutch bleed
pipe to torque tube.
5. Roadster Only - Position a piece of cloth in torque tube
aperture to collect spring clip (if dropped) and fluid loss.
6. Release clip and disconnect bleed hose from slave cylinder adaptor.
7. Plug slave cylinder to prevent fluid loss.
8. Release and remove bleed pipe assembly from support bracket.
Installation
1. Clean bleed hose assembly.
2. Remove plug from slave cylinder adaptor.
3. Install bleed hose and secure with clip.
4. Install bleed hose in support bracket.
5.Roadster Only - Install grommet sealing clutch bleed
pipe to torque tube.
6. Bleed clutch (see Workshop Manual procedure 08.00.AF Clutch Hydraulic System - Bleed).
7. Roadster Only - Install exhaust sysytem (see Workshop
Manual procedure 09.00.NB Exhaust System -
Excluding manifold/down pipes - Renew).
8. Coupe Only - Install deflector - front floor heatshield
(see Workshop Manual procedure 09.04.AA Heatshield
- Front Floor - Renew).
9. Lower vehicle on ramp.
Clutch Hydraulic System-Bleed-
Sportshift Only
08.00.AE
1. Raise vehicle on ramp.
2. Install Diagnostic tool and navigate to appropriate screen.
3. Position cloth around fluid reservoir to collect any spillage.
4. Remove fluid reservoir cap, en sure fluid level is correct
in reservoir.
5. Clean area around clutch bleed nipple.
6. Remove cap from bleed nipple.
7. Position bleed container containing clean hydraulic fluid, connect hose to bleed nipple.
8. Initiate bleed procedure on Diagnostic tool.
9. Loosen bleed nipple, allow air/fluid to escape and tighten bleed nipple.
10. Repeat procedure until air free fluid emerges.
11. Disconnect bleed hose, remo ve container, install dust
cap to bleed nipple.
12. Top-up fluid reservoir.
Fig. 2Warning
Always connect the battery earth (+ve) terminal first.
Repair Operation Time (ROT)
Before proceeding with the ne xt step, position a piece of
cloth in the torque tu be aperture to collect the spring clip
if dropped.
Caution
Always plug pipe ends to prevent ingress of dirt or moisture into the system.

Repair Operation Time (ROT)
ItemCode
Clutch Hydraulic System-Bleed
Warning
Observe all oil/fluid manufactu rers safety instructions
when handling components th at have been in contact
with transaxle oil.

Clutch Assembly (08.01)
May 2007 Workshop Manual 8-1-5
13. Remove Diagnostic tool.
14. Lower vehicle on ramp.
Clutch Hydraulic System-Bleed
08.00.AF
1. Raise vehicle on ramp.
2. Remove fluid reservoir cap and ensure fluid level is correct.
3. Clean area around clutch bleed nipple.
4. Remove cap from bleed nipple.
5. Position bleed container cont aining clean hydraulic fluid
and connect hose to bleed nipple.
6. Depress clutch pedal to floor 3 times and hold pedal down on third application.
7. Loosen bleed nipple allowing any air/fluid to escape.
8. Tighten bleed nipple.
9. Repeat procedure until air-free fluid emerges.
10. Disconnect bleed hose, remove container and install dust cap to bleed nipple.
11. Top-up fluid reservoir.
12. Lower vehicle on ramp.
Master Cylinder to Slave Cylinder Tube
Assembly-Renew
08.00.AJ
-Sportshift Only
Removal
1. Disconnect vehicle battery. 2. Raise vehicle on ramp.
3. Remove torque tube (see Workshop Manual procedure
05.01.CA Torque Tube - Remo ve for Access & Refit).
4. Remove grommet sealing clutch pipe to torque tube.
5. Remove clip, disconnect clutch pipe from slave cylinder adaptor.
6. Release clip securing transmi ssion harness to clutch pipe
mounting bracket.
7. Release clips (x4) securing clutch pipe to transmission harness.
8 . R e m o v e c l u t c h p i p e f r o m t o r q u e t u b e .
Installation
1. Install clutch pipe to torque tube.
2. Secure clutch pipe to tran smission harness using clips.
3. Secure transmission harne ss to clutch pipe mounting
bracket using clip.
4. Install clip and refit clutch pipe to slave cylinder adaptor.
5. Install grommet sealing clutch pipe to torque tube.
6. Install torque tube (see Workshop Manual procedure 05.01.CA Torque Tube - Remo ve for Access & Refit).
7. Bleed clutch hydraulics (see Workshop Manual procedure 08.00.AE Clut ch Hydraulic System -
Sportshift - Bleed).
8. Lower vehicle on ramp.
9. Connect vehicle battery.
Repair Operation Time (ROT)
Warning
Avoid skin / eye contact or in gestion of clutch fluid. If
skin or eyes are sp lashed with clutch fluid, rinse the
affected area immediately with plenty of water and
obtain medical attention. If clutch fluid is ingested, obtain immediate medical attention.
Caution
Clutch fluid must not be allowed to contact vehicle paint work. Remove spilt clutch fl uid from the paint work by
rinsing away with running water.
Warning
Brake / Clutch fluid is hygroscopic. If kept in opened
containers it will absorb water vapour. Use only brake
fluid from freshly opened co ntainers when topping-up
the brake fluid reservoir.
Before proceeding to the next step, position cloth around
fluid reservoir to collect any spillage.
Repair Operation Time (ROT)
Warning
Always disconnect the battery earth (- ve) terminal first.
Warning
When raising the vehicle on a ‘two post’ ramp, ensure
that the rear end of the vehicle is securely strapped to
the ramp. Failure to strap the rear of the vehicle down may lead to the vehicl e falling off the ramp.
Warning
Observe all oil/fluid manufact urers safety instructions
when handling components that have been in contact with transaxle oil.
Warning
Always connect the battery ea rth (+ve) terminal first.

Issue 5, January 2010 Workshop Manual 9-1-1
Exhaust (09.00)
Contents
Exhaust Overview .................................................. 9-1-2
Silencer Assembly (09.01) ..................................... 9-1-3Variable Flow Silencer Assembly ............................ 1-3
Maintenance ........................................................... 1-3 LH Catalyst & Pipe Assembly-Renew ...................... 1-3
RH Catalyst & Pipe Assembly-Renew ..................... 1-3
LH Exhaust Manifold-Renew-Roadster Only ........... 1-4
Heated Exhaust Gas Oxygen (HEGO) Sensor
- Remove and Install .............................................. 1-4
Silencer and Bypass Valve Assembly-Remove for
Access/Refit-Coupe Only........................................ 1-5
Silencer and Bypass Valve Assembly-Remove for
Access/Refit-Roadster Only .................................... 1-5
Silencer and Bypass Valve Assembly-Renew ........... 1-6
Exhaust Rear Silencer Mounting Rubber-Renew ..... 1-7
Exhaust System-Renew........................................... 1-7
Exhaust System (Excludi ng Manifold/Downpipes)
-Renew .................................................................. 1-8
Pipes and Supports (09.03) ................................... 9-2-1 Specifications.......................................................... 2-1
Maintenance ........................................................... 2-1RH/LH Catalyst and Pipe Assembly-Renew............. 2-1
Exhaust Centre Pipe-Renew ................................... 2-1
RH Exhaust Manifold-Renew.................................. 2-2
LH Exhaust Manifold-Renew .................................. 2-2
RH Exhaust Manifold Gasket-Renew ...................... 2-3
LH Exhaust Manifold Gasket-Renew....................... 2-3
Exhaust Gas Temperature Sensor-Renew................ 2-4
Exhaust Gas Heated Temperature Sensor-Renew ... 2-4
RH/LH Rear Exhaust Pipe Assembly-Renew............ 2-5

Exhaust Overview
Exhaust System (09.00)9-1-2 Workshop Manual Issue 5, January 2010
Exhaust System (09.00)
Exhaust Overview
The exhaust system consists of two four -branch manifolds, two catalytic converte rs, four oxygen sensors and a single
variable flow silencer assembly.
Exhaust gasses flow from the exhaust manifolds, through the catalysts and on to the rear silencer assembly.
• Two engine management oxygen sensors are mounted before the catalysts. • Two catalyst monitor oxygen sensors are mounted in
the catalysts between the primary and secondary
catalyst brick.
09-01-001
Four Branch Manifolds Catalytic Converter Flow Silencer
Oxygen Sensors

Silencer Assembly (09.01)
Exhaust (09.00)
Issue 5, January 2010 Workshop Manual 9-1-3
Exhaust (09.00)
Silencer Assembly (09.01)
Variable Flow Silencer Assembly
The rear silencer assembly has a variable fl ow path controlled by two bypass valves.
The system is intended to enhance top end performance in mo tor sport applications and will not operate in most normal
driving conditions.
By directing exhaust gasses through a modified path at high vehicle speeds, exhaust back pressure is reduced and top end
performance is enhanced.
As engine speed increase from idle, the bypass valve is open until the engine speed is 1500 rpm.
From 1500 rpm to 3000 rpm, the valve is closed
Above 3000 rpm the bypass valves state is load dependent (fully open at higher loads).
Maintenance
LH Catalyst & Pipe Assembly-Renew
Removal
1. Raise vehicle on ramp.
2. Remove rear exhaust silencer (refer to Workshop Manual procedure 09.00.KA Muffler & Bypass Valve
Assembly - Remove for Access & Refit).
3. Disconnect multiplugs (x2), HEGO sensors.
4. Release sensor lead from clip on heatshield.
5. Secure sufficient lengths of string to HEGO sensor multiplugs for assembly purposes.
6. Loosen LH and RH clamp nuts , catalysts to centre pipe.
7. Remove nuts (x3), catalyst to exhaust manifold.
8. With assistance, manoeuvre exhaust centre pipe assembly rearwards to release from catalysts.
9. With assistance, release and support weight of LH catalyst from exhaust manifold.
10. Manoeuvre HEGO sensor le ads and remove cable tie.
Release HEGO sensor leads from behind heat shield.
Secure cable tie. Remove string from HEGO multiplugs.
11. Remove catalyst assembly.
12. Remove and discard gasket. 13. Remove HEGO sensor
s (x2) from catalyst.
Installation
1. Clean catalyst, mating joint faces and HEGO sensors..
2. Install and tighten HEGO sensors (x2) to catalyst.
3. Apply proprietary exhaust se alant around pipe joints.
4. Install new gasket to exhaust manifold flange.
5. With assistance, position cata lyst, secure string (x2) to
HEGO multiplugs, feed sensor leads behind heat shield.
Install catalyst to exhaust manifold.
6. Install and torque tighten nuts (x3), catalyst to exhaust manifold.
7. Align centre pipe asembly to catalyst, torque tighten
clamp nuts.
8. Remove string (x2), conne ct multiplugs (x2), HEGO
sensors.
9. Secure sensor lead in clip on heatshield.
10. Install rear exhaust silencer (refer to Workshop Manual procedure 09.00.KA Muffler & Bypass Valve Assembly -
Remove for Access & Refit).
11. Lower vehicle on ramp.
RH Catalyst & Pipe Assembly-Renew
Repair Operation Time (ROT)
Repair Operation Time (ROT)