2010 ASTON MARTIN V8 VANTAGE Workshop Manual

Pipes and Supports (09.03)
Exhaust System (09.00)9-2-2 Workshop Manual May 2007
5. Install centre pipe to both catalysts and centre mountings. Do not torque clamp nuts at this stage.
6. Install pipe assembly exha ust rear - LH (refer to
Workshop Manual procedure 09.00.JB Pipe Assembly -
Exhaust - Rear - LH - Renew).
7. Install pipe assembly exhaust rear - RH (refer to Workshop Manual procedure 09.00.HB Pipe Assembly
- Exhaust - Rear - RH - Renew).
8. Align and torque tighten exhaust system nuts/bolts.
9. Lower vehicle on ramp.
RH Exhaust Manifold-Renew
Removal
1. Disconnect vehicle battery.
2. Raise vehicle on ramp.
3. Remove RH front wheel arch liner (refer to Workshop Manual procedure 01.02.GB Wheel Arch Liner - Front -
RH - Renew).
4. Loosen EGR pipe in valve.
5. Remove heatshield deflector, front floor (refer to Workshop Manual procedure 09.04.AA Heatshield -
Front Floor - Renew).
6. Remove (nuts x2) EGR pipe from manifold, discard
gasket and tie aside.
7. Remove nut (x8) securing manifold to cylinder head
(refer to Fig. 1).
8. Remove nut (x2) on engine mountings.
9. Raise engine by approximately 25mm. 10. Remove exhaust manifold from vehicle and discard
gasket.
11. Remove heatshield from manifold (bolts x4)
Installation
1. Clean exhaust manifold and mating face on engine. Install new gasket to engine.
2. Install heatshield to manifold (bolts x4)
3. Install manifold to engine.
4. Install nut (x8) securing manifold to cylinder head.
5. Lower engine.
6. Install nuts (x2) on engine mounts.
7. Install (nuts x2) EGR pipe from manifold, clean mating face and fit new gasket (torque).
8. Install heatshield deflector, front floor (refer to Workshop Manual procedure 09.04.AA Heatshield -
Front Floor - Renew).
9. Tighten EGR pipe in valve (torque).
10. Install RH front wheel arch liner (refer to Workshop
Manual procedure 01.02.GB Wheel Arch Liner - Front -
RH - Renew).
11. Lower vehicle on ramp.
12. Connect vehicle battery.
LH Exhaust Manifold-Renew
Removal
1. Disconnect vehicle battery.
2. Raise vehicle on ramp.
3. Remove heatshield deflec tor, front floor (refer to
Workshop Manual procedure 09.04.AA Heatshield -
Front Floor - Renew).
4. Remove LH front wheel arch liner (refer to Workshop Manual procedure 01.02.FB Wheel Arch Liner - Front -
LH - Renew).
Repair Operation Time (ROT)
A090069
Repair Operation Time (ROT)
ItemCode
Exhaust Manifold-Renew LH09.00.CB
WAR NI NG
TO AVOID PERSONAL INJURY, I.E. SEVERE BURNS TO
THE SKIN, ALLOW EXHAUS T SYSTEM TO COOL
DOWN BEFORE REMOVING EXHAUST SYSTEM COMPONENTS.

Pipes and Supports (09.03)
Exhaust System (09.00)
May 2007 Workshop Manual 9-2-3
5. Remove nuts (x8), securing manifold to cinder head
(refer to Fig. 1).
6. Remove exhaust manifold, remove and discard gasket.
Installation
1. Clean manifold and mating face on engine and install
new gasket to engine.
2. Install manifold to engine.
3. Install nuts (x8) securing manifold to cylinder head.
4. Install LH front wheel arch liner (refer to Workshop Manual procedure 01.02.FB Wheel Arch Liner - Front -
LH - Renew).
5. Install heatshield deflector, front floor (refer to Workshop Manual procedure 09.04.AA Heatshield -
Front Floor - Renew).
6. Lower vehicle on ramp.
7. Connect vehicle battery.
RH Exhaust Manifold Gasket-Renew
Removal
1. Remove wheel arch liner (refer to Workshop Manual procedure 01.02.GB Wheel Arch Liner - Front - RH -
Renew).
2. Loosen EGR pipe in valve.
3. Remove heatshield deflector, front floor (refer to Workshop Manual procedure 09.04.AA Heatshield -
Front Floor - Renew).
4. Remove nuts (x2), EGR pipe to manifold, discard gasket
and tie EGR pipe aside. 5. Remove nut (x8) securing ex
haust manifold to cylinder
head.
6. Remove nuts (x2) on engine mountings.
7. Raise engine by approximately 25mm. (care to be taken as inlet manifold can foul).
8. Remove exhaust manifold from vehicle and discard gasket.
Installation
1. Install new gasket to engine, clean mating face on engine.
2. Install manifold to engine.
3. Install nut (x8) securing manifold to cylinder head
(torque).
4. Lower engine.
5. Install nuts (x2) on engine mounts (torque).
6. Install (nuts x2) EGR pipe from manifold, clean mating face and fit new gasket (torque).
7. Install heatshield deflector, front floor (refer to Workshop Manual procedure 09.04.AA Heatshield -
Front Floor - Renew).
8. Tighten EGR pipe in valve (torque).
9. Install wheel arch liner (r efer to Workshop Manual
procedure 01.02.GB Wheel Arch Liner - Front - RH -
Renew).
LH Exhaust Manifold Gasket-Renew
Removal
1. Remove heatshield deflector, front floor (refer to Workshop Manual procedure 09.04.AA Heatshield -
Front Floor - Renew).
2. Remove LH wheel arch liner (refer to Workshop Manual procedure 01.02.FB Wheel Arch Liner - Front - LH -
Renew).
3. Remove nut (x8) securing manifold to cylinder head.
4. Remove manifold from vehicle and discard gasket.
Installation
1. Install new gasket to engine, clean mating face on engine.
2. Install manifold to engine.
3. Install nut (x8) securing manifold to cylinder head
(torque).
4. Install LH wheel arch liner (refer to Workshop Manual procedure 01.02.FB Wheel Arch Liner - Front - LH -
Renew).
Fig. 1
Repair Operation Time (ROT)
302306BA090070
Repair Operation Time (ROT)

Pipes and Supports (09.03)
Exhaust System (09.00)9-2-4 Workshop Manual May 2007
5. Install heatshield deflector, front floor (refer to Workshop Manual procedure 09.04.AA Heatshield -
Front Floor - Renew).
Exhaust Gas Temperature Sensor-Renew
Removal
1. Raise vehicle on ramp.
2. Remove rear exhaust silencer (refer to Workshop Manual procedure 09.00.KA Silencer and Bypass Valve
Assembly - Remove for Access and Refit).
3. Disconnect sensor multiplugs (x2.
4. Release sensor leads from clips (x2) on heatshield.
5. Secure sufficient lengths of string to sensor multiplugs for assembly purposes.
6. Loosen rear 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 sensor leads and remove cable tie. Release sensor leads from behind heat shield. Secure cable tie.
Remove string fr om multiplugs.
11. Remove catalyst assembly.
12. Remove and discard gasket.
13. Remove sensor from catalyst.
Installation
1. Clean catalyst mating joint faces.
2. Install and tighten sensor (x2) (torque).
3. Apply proprietary exhaust sealant around pipe joints.
4. Install new gasket to exhaust manifold flange.
5. With assistance, position catal yst, secure string (x2) to
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 assembly to catalyst, torque tighten
clamp nuts.
8. Remove string (x2), connect multiplugs (x2), sensors.
9. Secure sensor leads in clips on heatshield.
10. Install rear exhaust silencer (refer to Workshop Manual procedure 09.00.KA Silencer and Bypass Valve
Assembly - Remove for Access and Refit).
11. Lower vehicle on ramp.
RH/LH Rear Exhaust Pipe Assembly-
Renew
Removal
1. Raise vehicle on ramp.
2. Remove rear undertray.
3. Remove rear silencer assembly (refer to Workshop Manual procedure 09.00.KA Silencer and Bypass Valve
Assembly - Remove for Access and Refit).
4. Remove bolts (x4), cross brace.
5. Loosen clamp nut, release/remove rear intermediate pipe from centre pipe.
6. Remove rear intermediate pipe through subframe.
7. Remove bolts (x4), heat shields (x2).
8. Remove clamp nut, bolt and washers (x2) from rear intermediate pipe.
Installation
1. Clean rear intermediate pipe and mating faces on centre pipe.
2. Install clamp bolt, washers and nut.
3. Position heat shields (x2), install and torque bolts (x4).
4. Apply a proprietary exhaus t sealant to clamp joint.
5. Install rear intermediate pipe to centre pipe.
6. Align rear intermediate pipe to silencer.
7. Install rear silencer assembly (refer to Workshop Manual procedure 09.00.KA Silencer and Bypass Valve
Assembly - Remove for Access and Refit).
8. Torque tighten clamp nut.
9. Install cross brace, install and torque tighten bolts (x4).
10. Install rear undertray.
11. Lower vehicle on ramp.
Repair Operation Time (ROT)
Repair Operation Time (ROT)
ItemCode
Rear Exhaust Pipe Assembly-Renew RH09.00.HB
Rear Exhaust Pipe Assembly-Renew LH09.00.JB
WAR NI NG
TO AVOID PERSONAL INJURY, I.E. SEVERE BURNS TO
THE SKIN, ALLOW EXHAUS T SYSTEM TO COOL
DOWN BEFORE REMOVING EXHAUST SYSTEM COMPONENTS.

Pipes and Supports (09.03)
Exhaust System (09.00)
May 2007 Workshop Manual 9-2-5

Pipes and Supports (09.03)
Exhaust System (09.00)9-2-6 Workshop Manual May 2007

May 2007 Workshop Manual 10-1-1
Fuel (10.00)
Contents
Fuel Tank and Lines (10.01) ................................ 10-1-2Description ............................................................. 1-2 Fuel Tank............................................................... 1-3
Fuel Pumps ............................................................ 1-3
Jet Pumps .............................................................. 1-4
Filler Neck and Check Valve .................................. 1-4
Valves and Sensors ................................................. 1-5
Fuel System Schematic ........................................... 1-5
Evaporative Loss System ......................................... 1-6 System Operation .................................................. 1-6
Fuel Tank Vents and Control Valves ....................... 1-6
Safety Precautions .................................................. 1-7
Specifications.......................................................... 1-7
Maintenance ........................................................... 1-8 Fuel System ........................................................... 1-8
Fuel Filter Assembly-Renew .. ................................. 1-8
Fuel Pump and Reservoir Assembly-Renew ............ 1-9
Fuel Tank and Canister Assembly-Renew ............. 1-11
Fuel Tank and Canister Assembly-Remove
for Access/Refit ................................................... 1-13
Fuel Tank Sender Assembly-Renew ...................... 1-15
Fuel Vapour Pipe Assembly-Renew ...................... 1-16
Fuel Supply and Vapour Pipe Assembly-Renew .... 1-17
Manifold Supply Fuel Pipe Assembly- Renew ....... 1-17

Fuel Tank and Lines (10.01)
Fuel (10.00)10-1-2 Workshop Manual May 2007
Fuel (10.00)
Fuel Tank and Lines (10.01)
Description
This vehicle uses a return less fuel system in which the fuel pump, controlled by the fuel pump driver module, is run to
supply fuel through one in-tank filter to the fuel rail (Refer to ’Fuel Charging System (03.04)’, page 3-5-1). A pressure senso r
and a temperature sensor are fitted on th e primary fuel rail. The fuel pump speeds are varied as required to regulate the
fuel pressure in the fuel rails.
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Fuel Tank and Lines (10.01)
Fuel (10.00)
May 2007 Workshop Manual 10-1-3
Fuel Tank
The fuel tank incorporates a single filler neck and check valve, internal fuel pump, internal fuel filter, a sender unit and an
‘on board refuelling vapour recovery’ system.
Fuel Pumps

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The modular fuel pump is immersed in the base of the fuel
tank. The pump can deliver up to 150 litres/hour. The in-
tank fuel line connects to the external line using a quick-fit
connector in the base of the fuel tank. During normal running, pressu
rised fuel from each fuel
pump passes from the tank, through an 3 micron in-tank fuel
filter to one of the two fuel rails on the engine.
Fuel temperature is measured on the primary fuel rail. If fuel
temperature becomes excessive, the fuel pressure is
increased to prevent fuel vaporisation (boiling).
Fuel pressure is measured by sensors on each fuel rail. The
fuel pressure to each rail is regulated as required by
continuously changing the run speed of the associated fuel
pump. Maximum pressure in the system is limited to 5.3 bar
by in-tank pressure regulators.
A constant head of fuel is maintained in the fuel pump
modules to ensure that the pumps cannot run dry in a ‘low
fuel’ situation.

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