2010 ASTON MARTIN V8 VANTAGE alternator belt

Engine Sealing (03.10)
Engine (03.00)
Issue 5, Janauary 2010 Workshop Manual 3-10-1
Engine (03.00)
Engine Sealing (03.10)
Specifications
Maintenance
Engine Timing Cover - Renew
1. Remove the front subframe (refer to Workshop Manual procedure 02.01.BA Subframe Assembly - Front -
Remove for Access and Refit).
2. Put an applicable container in position under the engine
to collect drained oil.
3. Remove the sump drain plug and drain the oil from the engine.
4. Remove the oil tank assembly (refer to Workshop Manual procedure 03.02.CA Tank Assembly - Oil
Cooler - Renew).
5. Drain cooling system (refer to Workshop Manual procedure 03.03.AD Coolant - Drain and Refill).
6. Remove the left cam cover (Refer to ’Left Side Cam Cover - Remove and Install’, page 3-10-4) 7. Remove the outer and inner seals from the left cam
cover.
8. Remove the right cam cover (Refer to ’Right Side Cam Cover - Remove and Install’, page 3-10-9).
9. Remove the outer and inner seals from the right cam cover.
10. Release the clips and disconnect the two coolant hoses from the coolant manifold.
11. Release the clip and disconnect the hose from oil the separator.
12. Remove the four M6 Torx screws that attach the coolant manifold to the cylinder heads (Refer to Figure 1).
Figure 1
13. Release the coolant manifold from the coolant pipe.
14. Disconnect the electrical connector for the temperature sensor.
15. Remove the coolant manifold.
16. Remove and discard the two O-rings from the manifold.
17. Loosen the three M6 attachment screws for the water pump pulley (Refer to Figure 2).
Figure 2
18. Turn the auxiliary drive be lt tensioner to release the
tension from the drive belt.
19. Remove the drive belt.
20. Remove the three M6 screws that attach the water pump pulley and remove the pulley.
Torque Figures
DescriptionNm.lb./ft.
Cam cover 10 7
Dipstick tube 6 4
Timing cover:
Bolts 1 to 7, 9 to 18 and 20 to 27
Bolts 8 and 19
12

10
9

7
Crankshaft pulley bolt 320 236
Alternator mounting bracket 21 15.5
Alternator 40 30
Coolant manifold 9 6.5
Coolant pump 12 9
Coolant pump pulley 10 + 45° 7 + 45°
PAS pump 21 15.5
Accessory drive belt idler pulleys 40 30
Accessory drive be lt tensioner 40 30
Heater hose brackets:
M6 Bolts
M5 Nuts
12

5
9

3.7
Harness support brackets:
M5 Nut
M6 Screw
M8 Screw
5

10
25
3.7

7
18.5
Repair Operation Time (ROT)
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Engine Sealing (03.10)
Engine (03.00)3-10-2 Workshop Manual Issue 5, Janauary 2010
21. Remove the M10 bolt that attaches the auxiliary drive belt tensioner and remove tensioner (Refer to Figure 3).
Figure 3
22. Remove the two bolts that attach the inspection cover to lower crankcase and remove the cover.
23. Install the tool (303-1185) to hold the flywheel. Install and tighten the two bolts.
24. Remove and discard the M16 screw that attaches the crankshaft pulley.
25. Install the thrust-button of tool (303 -1186) into crankshaft.
26. Put the tool into the pulley.
27. Attach the tool with the two bolts.
28. Turn the centre bolt clockwise to withdraw the pulley from the crankshaft.
29. Collect the crankshaft pulley, locking ring and the thrust button for the special tool.
30. Remove the special tool from the pulley.
31. Remove and discard the O-ring seal from the pulley.
32. Remove the bolt that attaches the alternator idler pulley and remove the pulley.
33. Remove the bolt that attaches the idler pulley for the air- conditioning compressor and remove the pulley.
34. Put an applicable container under the oil filter to collect drained oil.
35. Remove the oil filter.
36. Release the oil separator drain tube from the timing cover.
37. Release the clip for the oil separator drain tube from the bracket.
38. Release the cover for the battery cable from the alternator. 39. Remove the nut that attaches the battery cable to the
alternator and remove the cable. (Refer to Figure 4).
Figure 4
40. Disconnect the electrical connector from the alternator.
41. Remove the M8 bolt that attaches the top of the alternator.
42. Remove the M10 bolt and the nut that attaches the bottom of the alternator and remove the alternator.
43. Remove the three Torx bolts that attach the alternator mounting bracket to the cylinder block.
44. Remove the bracket (Refer to Figure 5).
Figure 5
45. Remove the three M8 bolts that attach the PAS pump to the mounting bracket and move the pump away.
WAR NI NG
DO NOT GET USED ENGINE OIL ON YOUR SKIN.
USED ENGINE OIL CAN BE HARMFUL.
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Engine Sealing (03.10)
Engine (03.00)3-10-4 Workshop Manual Issue 5, Janauary 2010
20. Put the alternator in position.
21. Install the M8 bolt that attaches the top of the alternator.
22. Install the M10 nut and bolt that attaches the bottom of the alternator.
23. Torque tighten the alternator attachment bolts.
24. Connect the battery cable to the alternator.
25. Install and torque the nut that attaches the battery cable.
26. Install the cover for the cable connection.
27. Connect the electrical connector to the alternator.
28. Apply new engine oil to the seal on a new oil filter.
29. Install the new oil filter.
30. Install the drain tube for the oil separator into the clip in the bracket.
31. Install the drain tube for the oil separator into timing cover.
32. Install the idler pulley for the air conditioning compressor.
33. Install and torque the M10 bolt that attaches the idler pulley.
34. Install the alternator idler pulley.
35. Install and torque the M10 bolt that attaches the idler pulley.
36. Install the auxiliary drive belt tensioner.
37. Install and torque the M10 bolt that attaches the tensioner.
38. Put the water pump pulley in position.
39. Install the three M6 bolts that attach the water pump pulley.
40. Turn the auxiliary drive be lt tensioner until you can
install the drive belt.
41. Torque tighten the three M6 water pump pulley bolts.
42. Clean the coolant manifold and the mating faces on the cylinder heads.
43. Install two new O-ring seals into the coolant manifold.
44. Put the coolant manifold in position.
45. Connect the electrical connector for the temperature sensor.
46. Install the coolant pipe in the manifold.
47. Install and torque tighten the four M6 Torx bolts that attach the coolant manifold to the cylinder heads.
48. Connect the three coolant hoses to the coolant manifold and install the hose clips.
49. Connect the engine breather to the oil separator.
50. Clean the left and right cam covers.
51. Install the inner and outer seals on the left cam cover.
52. Install the left cam cover (Refer to ’Left Side Cam Cover - Remove and Install’, page 3-10-4).
53. Install the inner and outer seals on the right cam cover.
54. Install the right cam cover (Refer to ’Right Side Cam Cover - Remove and Install’, page 3-10-9).
55. Install the front subframe (refer to Workshop Manual procedure 02.01.BA Subframe Assembly - Front -
Remove for Access and Refit). 56. Install the oil tank assembly
(refer to Workshop Manual
procedure 03.02.CA Tank Assembly - Oil Cooler -
Renew).
57. Fill the cooling system (refer to Workshop Manual procedure 03.03.AD Coolant - Drain and Refill).
Left Side Cam Cover - Remove and
Install
Removal
1. Disconnect the battery earth cable.
2. Remove the front crush brace. (Refer to procedure 01.01.LC - Front Crush Brace).
3. Remove the left side front crush bar for the body reinforcement. (Refer to procedure 01.01.AC - Left Side
Front Crush Bar for the Body Reinforcement).
4. Disconnect the breather pi pes from the cam cover and
the oil tank Y-piece.
5. Use applicable caps to seal the open ports.
6. Remove the ignition coil cover.
7. Disconnect the electrical connector from each of the four ignition coils.
8. Disconnect the electrical connector from the Variable
Valve Timing (VVT) solenoid.
9. Release the fir tree clip that attaches the wiring harness for the ignition coils.
10. Move the wiring harness for the ignition coils away.
11. Release the wiring harness for the injectors from the mounts.
12. Cut and remove the three cable ties that attach the rear of the wiring harness for the injectors.
13. Release the purge pipe an d heater pipe from the two
clips on the wiring harness bracket.
14. Remove the two nuts and three screws that attach the front bracket for the wiring harness.
15. Remove the three screws that attach the rear bracket for the wiring harness.
16. Cut and remove the four cable ties that attach the rear
of the wiring harness to the front bracket.
17. Remove the rear bracket for the wiring harness.
18. Remove the front bracket for the wiring harness.
19. Remove the screw that attaches each of the four ignition coils.
20. Remove the four ignition coils.
21. Remove the 14 screws that attach the cam cover to the
engine.
Repair Operation Time (ROT)
ItemCode
Left Side Cam Cover - Remove and
Install 03.10.AS
Note: When you remo ve the cam cover attachment bolts in
the step that follows , record their installed positions in the
cam cover.

Engine Sealing (03.10)
Engine (03.00)
Issue 5, Janauary 2010 Workshop Manual 3-10-11
Removal
1. Remove the left side cam cover (Refer to ’Left Side Cam Cover - Remove and Install’, page 3-10-4).
2. Remove the right side cam cover (Refer to ’Right Side Cam Cover - Remove and Install’, page 3-10-9).
Install
1. Install the left side cam cover (Refer to ’Left Side Cam Cover - Remove and Install’, page 3-10-4).
2. Install the right side cam cover (Refer to ’Right Side Cam Cover - Remove and Install’, page 3-10-9).
Engine Timing Cover-Renew (with Engine
Removed
)
Removal
1. Remove the engine assembly (refer Workshop Manual procedure 03.00.AA Engi ne Assembly - Renew).
2. Position drain container.
3. Remove the drain plug and drain the oil from the sump.
4. Remove the left cam cover (Refer to ’Left Side Cam Cover - Remove and Install’, page 3-10-4).
5. Remove the right cam cover (Refer to ’Right Side Cam Cover - Remove and Install’, page 3-10-9).
6. Release the hose clips and disconnect the two coolant hoses from the coolant manifold.
7. Release the hose clip and di sconnect the hose from the
oil separator.
8. Remove the four Torx bolts that attach the coolant manifold to cylinder heads (refer to Figure 1).
Figure 1
9. Release the coolant mani fold from coolant pipe,
disconnect the temperature sensor multiplug.
10. Remove the coolant manifold.
11. Remove and discard the two O-rings from the coolant manifold. 12. Loosen the three water pump pulley bolts (refer to
Figure 2).
Figure 2
13. Use an applicable socket bar to release the auxiliary
drive belt tensioner.
14. Remove the drive belt.
15. Remove the three bolts and remove the water pump pulley.
16. Remove the bolt that attaches the auxiliary drive belt tensioner.
17. Remove the tensioner (refer to Figure 3).
Figure 3
18. Remove the two bolts that attach the inspection cover to the lower crankcase. Remove the cover.
19. Install tool (303-1185) to hold flywheel. Install and tighten the two bolts .
20. Install the thrust button of tool (303 -1186) into the crankshaft.
21. Put the tool in position in the pulley. Attach the tool with the two bolts. Tighten the centre bolt and remove
the pulley from the crankshaft.
22. Collect the crankshaft pulley, locking ring and the special tool thrust button.
23. Remove the special tool from the pulley.
24. Remove and discard the O-ring seal from pulley.
25. Remove the bolt that attaches the alternator idler pulley.
Repair Operation Time (ROT)
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Engine Sealing (03.10)
Engine (03.00)
Issue 5, Janauary 2010 Workshop Manual 3-10-13
38. Remove the four Torx bolts that attach the PAS pump mounting bracket to the cylinder block. Remove the
bracket (refer to Figure 9).
Figure 9
39. Remove the 27 bolts that attach the timing cover to the engine. Collect the bracet for the oil separator drain
tube. Remove the timing cover.
40. Remove the outer and inner rubber seals from the timing cover (refer to Figure0).
Figure0
41. Remove the front crankshaft oil seal from timing cover.
Installation
1. Clean the timing cover and mating face on engine.
2. Install the inner and outer seals into timing cover.
3. Apply 3mm x 12mm beads of sealant to the eight joints
on the engine.
4. Install the timing cover. Put the oil separator drain tube bracket in position. Install the 27 bolts and torque the
bolts in the specified sequence. 5. Using tool (303-750), instal
l front crankshaft oil seal.
Remove special tool and seal protector.
6. Clean crankshaft pulley and mating face on crankshaft.
7. Lubricate and install new O-ring seal in crankshaft pulley.
8. Install crankshaft pulley, locking ring and new pulley bolt.
9. Torque tighten crankshaft pulley bolt. Remove special tool (303-1185) from crankcase.
10. Install inspection cover to lower crankcase, install and tighten bolts (x2).
11. Install PAS pump mounting bracket, install and torque tighten Torx bolts (x4).
12. Install PAS pump, install and torque tighten bolts (x3).
13. Install alternator mounting bracket, install and torque tighten Torx bolts (x3).
14. Install alternator, install bolt and nut/bolt and torque tighten
15. Connect battery cable, install and torque tighten nut, secure cover. Connect multiplug.
16. Lubricate seal, install new oil filter.
17. Install oil separator drai n tube clip in bracket.
18. Install oil separator drain tube to timing cover.
19. Install A/C compressor idler pulley, torque tighten bolt.
20. Install alternator idler pulley, torque tighten bolt.
21. Install auxiliary drive belt te nsioner, torque tighten bolt.
22. Install water pump pulley, install bolts (x3).
23. Using a suitable socket ba r, release auxiliary drive belt
tensioner, install drive belt.
24. Torque tighten water pump pulley bolts (x3).
25. Clean coolant manifold and mating faces on cylinder heads.
26. Install new O-ring seals (x2) to coolant manifold.
27. Position coolant manifold, connect temperature sensor
multiplug, install coolant pipe in manifold.
28. Install and torque tighten Torx bolts (x4) that attach the coolant manifold to cylinder heads.
29. Connect coolant hoses (x3) to coolant manifold and
secure clips.
30. Connect engine breather to oil separator.
31. Clean left and right cam covers.
32. Install the right cam cover (Refer to ’Right Side Cam Cover - Remove and Install’, page 3-10-9).
33. Install left cam cover (Refer to ’Left Side Cam Cover -
Remove and Install’, page 3-10-4).
34. Install the engine assembly (refer to Workshop Manual procedure 03.00.AA Engine Assembly - Renew).
Caution
Make sure the cranks haft front oil seal mating faces are
clean and dry.
Caution
Do not remove the crankshaft front oil seal protector
until the oil seal is correctly installed.
If you do, the oil seal can be damaged.
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Caution
The bolt thread in the cran kshaft must be cleaned out
before a new crankshaft pulley retaining bolt is installed.
Note: Check the crankshaft pulley and locking ring for damage.

Instrument Cluster (13.01)
Information, Gauge and Warning (13.00)
May 2007 Workshop Manual 13-1-3
Information and Warning Lamps
Name / FunctionDescriptionSymbolInput SignalPower
On Check
General Warning
– Amber/Red Controlled internally by the DIM. It is used in conjunction with
several text messages to indicate information to the driver. Internal
SRS (Airbag) Controlled externally by the SRS module and indicates a fault in the SRS module. CAN Yes (5 Seconds)
High Engine
Coolant Temp. This tell tale is controlled internally by the DIM. Activated
when the engine coolant temperature signal from the CAN bus
reaches a pre defined value. (The
actual symbol is not lit, only
the red LED.) CAN
DSC Controlled externally by the ABS/DSC module. Indicates when the system is in operation or when it is turned off. The tell tale
is triggered by a CAN signal. CAN Yes (5 Seconds)
ABS Controlled externally by th e ABS/DSC module. Indicates a
fault in the ABS system. The tell tale is triggered by a CAN
signal. CAN Yes (5 Seconds)
Rear Fog Lights Controlled externally by the SRS module. Indicates that the
rear fog lights are turned on. The tell tale is triggered by a CAN
signal. CAN Yes (5 Seconds)
Seat Belts Controlled externally by the CEM. Indicates that the seat belts are not fastened properly. The tell tale is triggered by a CAN
signal. CAN Yes (5 Seconds)
Brake (General) Controlled externally by either the CEM or the ABS / DSC module. It indicates low brake fluid level, brake fault and park
brake. The tell tale is triggered by two low side inputs or a CAN
signal. Low side x 2
and
CAN Ye s ( 5 S e c o n d s )
Side Lights Controlled externally by th e CEM. Indicates that the side lights
are on. High side
Oil Pressure Controlled exte rnally by the PCM. Indicates low oil pressure.
The tell tale is triggered by a CAN signal. CAN Yes (5 Seconds)
Battery Charge Controlled externally by th e CEM. Indicates that the alternator
is no longer charging the battery properly. The tell tale is
triggered by a CAN signal. CAN Yes (5 Seconds)
Fuel Level Low Controlled internally by the DIM. Activated when the fuel level drops below a pre defined value. The fuel information is
provided from the CAN bus. The symbol is not lit, only the
amber LED. CAN
Turn Left/Right Controlled externally by th e CEM. The tell tale is triggered by a
CAN signal. CAN
High Beam Controlled externally by the CEM. Indicates that the high beam is switched on. The tell tale is triggered by a CAN signal. CAN
Check Engine Controlled externally by the PCM. Indicates a fault in the engine management system. The te ll tale is not connected to
the microprocessor. Low side
Tyre Pressure Controlled by the DIM. In dicates a low or rapid change in the
tyre pressure or a tyre pressure monitoring system fault. Low side Yes (5 Seconds)
Not Used
PATS Controlled externally by the PCM. Indicates key acceptance status. Low side

Alternator and Regulator System (14.02)
Power Supply (14.00)
May 2007 Workshop Manual 14-2-1
Power Supply (14.00)
Alternator and Regulator System (14.02)
Description
The alternator installed to this vehicle is a Denso, SC1, 120
amp rating, with a 14.4 volt regulator.
The Alternator has an 'Altmon' signal that goes to and from
the PCM via a wire in the 3 way connector.
The ‘Altmon’ signal is monitored by the PCM which adjusts
ignition timing and fuelling if necessary to maintain idle
speed when the alternator is charging.
Specifications
Maintenance
Alternator-Renew
Removal
1. Battery isolation switch ‘OFF’.
2. Disconnect breather pipe qu ickfits (x2) from air cleaner
duct.
3. Remove throttle body du ct for access (clips x3).
4. Release tensioner and slip belt from idler.
5. Move belt off alternator pulley.
6. Reposition oil tank (to release alternator).
7. Remove breather pipe (quick fit).
8. Remove pipes (x2) fr om oil tank, tie aside.
9. Remove bolts (x4) securing tank to body, support tank and move aside to left side of engine bay. 10. Disconnect top hose from engine (clip x1) tie aside
(catch coolant).
11. Raise vehicle on ramp.
12. Remove undertray (see Workshop Manual procedure 01.02.NB Undertray - Front - Renew).
13. Remove bolts (x3) securing oil thermostat to body (allows oil tank more sideways movement).
14. Remove road wheel/s.
15. Remove oil filter and renew (see Workshop Manual procedure 03.02.AB Filter - Oil Canister Renew).
16. Reposition heatsheild to gain access to top bolt.
17. Unclip harness from bracket for access to top bolt and move aside.
18. Remove top securing nut and bolt.
19. Remove nut from bottom fixing and withdraw bolt (will foul on front subframe).
20. Lever alternator forward to release clamping of sliding bushes.
21. Using suitable grips remove bottom/ front sliding bush together with bolt.
22. Position alternator for access, disconnect battery (nut x1) lead and multiplug.
23. Lower ramp.
24. Remove alternator via front of engine (oil tank).
Installation
1. Install alternator.
2. Raise ramp.
3. Connect battery lead and multiplug to alternator.
4. Position alternator to bracket, install top fixing nut and bolt (do not tighten).
5. Install bottom bolt with sliding bush into bracket (through alternator).
6. Install nut to bottom bolt and tighten (torque).
7. Tighten top nut and bolt (torque)
8. Install oil filter and re new (see Workshop Manual
procedure 03.02.AB Filter - Oil Canister Renew).
9. Clip harness to bracket.
10. Reposition heatsheild to original position.
11. Install bolts (x3) securing oil thermostat to body (torque).
12. Install undertray (see Workshop Manual procedure 01.02.NB Undertray - Front - Renew).
13. Install road wheel/s
14. Lower vehicle on ramp.
15. Reposition oil tank.
16. Connect top hose to engine (clip x1).
17. Position tank to body and fit bolts (x4) (torque).
18. Install oil pipes to tank.
19. Connect breather hose.
20. Fit belt to alternator pulley.
Torque Figures
DescriptionNmlb/ft
Alternator mounts 43-52 32-38.5
Repair Operation Time (ROT)




Alternator and Regulator System (14.02)
Power Supply (14.00)14-2-2 Workshop Manual May 2007
21. Release tensioner and slip belt on idler.
22. Install throttle body duct.
23. Connect breather pipe quickf its (x2) to air cleaner duct.
24. Battery isolation switch ‘ON’.
25. Top up coolant.