Aston Martin V8 Vantage Workshop Manual
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Aston Martin V8 Vantage Workshop Manual

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Table of Contents

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Workshop Manual
Issue 1

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Summary of Contents for Aston Martin V8 Vantage

  • Page 1 Workshop Manual Issue 1...
  • Page 2 Fax: (01926) 644733 Aston Martin are constantly seeking to improve the specification, design and production of their vehicles and alterations take place accordingly. While every effort has been made to ensure the accuracy of this Manual, it should not be regarded as an infallible guide to current specifications of any particular vehicle.

  • Page 3: Table Of Contents

    Contents V8 Vantage Workshop Manual Contents Brake System (06.00) Description ............6-1-2 Introduction Front Disc Brake (06.03) ........6-2-1 Welcome ..............0-0-6 Rear Disc Brakes (06.04) ........6-3-1 Safety Precautions..........0-0-7 Hand Brake (06.05) ..........6-4-1 Lifting and Jacking..........0-0-9 Brake Actuation System (06.06) ......6-5-1 Vehicle Recovery ..........0-0-10...
  • Page 4 Contents Electric Distribution/Electronic Control (18.00) Wiring and Circuit Protection (18.01) ....18-1-2 Vehicle Control System (18.08) ......18-2-1 Electronic Features (19.00) Active Anti-Theft System (19.01)......19-1-2 Appendix & Glossary Fluids/Capacities..........20-1-2 Abbreviations ............. 20-1-3 Terms..............20-1-3 Special Tools - Pictorial Index ......20-1-4 Specialist Tool Operation ........

  • Page 5: Introduction

    Contents Introduction Contents ..............0-3 Welcome..............0-0-6 Chapters ..............0-6 Chapter Navigation ..........0-6 Page Numbering ............. 0-6 Systems Classification Coding........ 0-6 Special Tools............0-0-6 Location References..........0-6 Warnings, Cautions and Notes......0-0-6 Repairs and Replacements ........0-6 Safety Precautions ..........0-0-7 Battery Disconnection ..........0-7 Air Conditioning (A/C) System........

  • Page 6: Welcome

    Where replacement parts are required, it is essential that Suspension together in one chapter. The structure now used only genuine Aston Martin parts are used. Your attention is places Steering and Suspension into their own chapters. drawn to the following points concerning repairs and the When required references are made out to other chapters.

  • Page 7: Safety Precautions

    Safety Precautions Safety Precautions • Chemicals based on solvents such as paint should not be sprayed in a confined space; work areas used for such All service workshops are a source of potential danger and operations should be well ventilated and fume extraction repair work should only be performed by technically trained equipment should be utilised.

  • Page 8: Tools And Equipment

    Safety Precautions Tools and Equipment Environmental Protection It is illegal to pour used oil on the ground, down sewers or • Do not leave tools, equipment, spilt oil, etc. around or on drains, or into water courses. The burning of used engine oil the work area.

  • Page 9: Lifting And Jacking

    Lifting and Jacking Lifting and Jacking Lifting Safety Workshop Hoist Use of a workshop hoist is recommended for all operations • Recommended procedures for lifting, jacking and where vehicles must be raised. Follow manufacturers towing must be strictly observed to ensure personal instructions.

  • Page 10: Vehicle Recovery

    Vehicle Recovery Vehicle Recovery Adhere to Towing Regulations In certain countries the registration number of towing General vehicle and an ‘ON TOW’ sign or warning triangle must be Preferred method of vehicle recovery is by flat bed displayed in a prominent position at the rear of vehicle being transporter.

  • Page 11: Vehicle Identification Number

    Vehicle Identification Number Vehicle Identification Number The Vehicle Identification Number (VIN) is a 17 character number which uniquely identifies the vehicle and gives fundamental data on the build site, date and initial configuration of the vehicle. Code for AML Restraint System Transmission and Steering Body Type Engine Type...

  • Page 12: Body System (01.00)

    Body System (01.00) Contents Undertray Vehicle Set-Renew ........ 5-2 Body Structure (01.01)...........1-1-3 Overview ..............1-3 RH/LH Front Wheel Arch Liner-Renew ....5-2 Front End (01.02)...........1-2-1 RH/LH Rear Wheel Arch Liner-Renew ....5-2 Front Wings ............2-1 Mirrors (01.09) ............1-6-1 Specifications............
  • Page 13 Remote Transmitter..........10-1 Fuel Filler Assembly..........10-1 Boot Emergency Release ........10-1 Specifications ............10-2 Maintenance ............10-2 RH/LH Front Door Latch Assembly-Renew ...10-2 0114BD|Latch Assembly - Hood - Renew ....10-2 RH/LH External Front Door External-Renew ..10-2 Reduced Guard Switch-Renew......10-3 Passenger Airbag On/Off Switch-Renew ....10-3 Tailgate Release Switch-Renew......10-3 Passenger Window Lift Switch-Renew ....10-3 Driver Window Lift Switch-Renew......10-3...

  • Page 14: Body Structure (01.01)

    Body Structure (01.01) Body System (01.00) Body System (01.00) Body Structure (01.01) Overview The all aluminium body underframe is bonded using an immensely strong hot-cured XD4600 red adhesive. The rear quarter panels, roof and side mouldings are bonded to the structure using cold-cured 2810 MV adhesive. The curing cycle is improved by using a hot air impingement system.
  • Page 15 Body Structure (01.01) Body System (01.00) 1-1-4 Workshop Manual October 2005...

  • Page 16: Front End (01.02)

    Front End (01.02) Body System (01.00) Body System (01.00) Front End (01.02) Wing Standard (mm) Item Front Wings Tolerance ±0.75 +0.5 / -0.0 ± 0.75 ±0.5 Specifications Flush -0.0 -0.5 Tolerance ±1.5 +0.0 / -0.5 ±1.5 ±0.5 Taper Symmetry Torque Figures Description Wing Top Wing Top Single nut...
  • Page 17 Front End (01.02) Body System (01.00) 1-2-2 Workshop Manual October 2005...

  • Page 18: Body Closures (01.03)

    Body Closures (01.03) Body System (01.00) Body System (01.00) Body Closures (01.03) Tailgate Specifications Doors Tailgate Standard (mm) Item Door Standard (mm) Nominal gap Item Tolerance ±0.75 ±1.0 Nominal gap 3.00 3.00 3.75 ± 0.75 Flush -0.5 Tolerance ±0.75 ±1.0 ±1.0 Tolerance...

  • Page 19: Maintenance

    Body Closures (01.03) Body System (01.00) Maintenance Installation 1. Position hood to hinge and install bolts (x4). Tailgate Assembly-Renew 2. Install hood ball studs. Repair Operation Time (ROT) 3. Install Buffers to hood. Item Code 4. Install sound deadening. Tailgate Assembly-Renew 01.03.GG 5.

  • Page 20: Interior Trim (01.05)

    Interior Trim (01.05) Body System (01.00) Body System (01.00) Interior Trim (01.05) This section covers removal and installation of the interior moldings and trim panels. In many instances, one component overlaps another component. If this condition is found, it will be necessary to loosen or remove the overlapping component before removal, to prevent damage to either component.

  • Page 21: Rh/Lh Upper Rear Pillar Panel Assembly-Renew

    Interior Trim (01.05) Body System (01.00) Installation 2. Remove screw securing courtesy light console to header (see Fig. 1). 1. Position sun visor and install screws (x2). 2. Install courtesy light console. 3. Install grille. RH/LH Upper Rear Pillar Panel Assembly-Renew Repair Operation Time (ROT) Item...

  • Page 22: Rear Header Panel Assembly-Renew

    Interior Trim (01.05) Body System (01.00) Installation 2. Remove screw securing courtesy light console to header (see Fig. 1). 1. Install rear header panel assembly. 2. Install RH moulding assembly quarter trim upper (see Workshop Manual procedure 01.05.CX Moulding Assembly - Quarter Trim Upper - RH - Renew).

  • Page 23: Rh/Lh Door Trim Upper Veneer Panel-Renew

    Interior Trim (01.05) Body System (01.00) 6. Remove door trim panel bolts (x5). 2. Install speaker grille, clips (x3) and screws (x2). 7. Lift trim out and up to release trim from door frame and 3. Install upper veneer door trim panel, screws (x9) and disconnect multiplugs (x2).

  • Page 24: Rh/Lh Upper Quarter Moulding Trim-Renew

    Interior Trim (01.05) Body System (01.00) Installation Repair Operation Time (ROT) Item Code 1. Install speaker (nuts x3). Lower Panel Assembly Quarter Trim- 01.05.CS 2. Connect speaker multiplug. Renew 3. Feed seat belt harness through panel and secure panel Removal to body.

  • Page 25: Luggage Compartment Floor Rear Carpet Assembly-Renew

    Interior Trim (01.05) Body System (01.00) Removal 1. Release and remove rear luggage compartment floor carpet. 1. Remove screws (x2) securing tailgate striker and remove 2. Remove front floor carpet retainers (x6). striker. 3. Remove luggage compartment front floor carpet. 2.
  • Page 26 Interior Trim (01.05) Body System (01.00) 3. Remove screws (x4) that secure centre stack assembly to IP (see Fig. 1). Fig. 1 4. Release centre stack assembly and disconnect multiplugs (x12). Installation 1. Position centre stack assembly and install multiplugs (x12).
  • Page 27 Interior Trim (01.05) Body System (01.00) 1-4-8 Workshop Manual October 2005...

  • Page 28: Exterior Trim (01.08)

    Exterior Trim (01.08) Body System (01.00) Body System (01.00) Exterior Trim (01.08) LH Side Strake Mesh-Renew Maintenance Repair Operation Time (ROT) Item Code Radiator Grille-Renew Side Strake Mesh-Renew 01.08.CF Removal Repair Operation Time (ROT) Item Code 1. Remove nuts (x3) mesh to side strake. Radiator Grille-Renew 01.08.AA 2.

  • Page 29: Front Undertray-Renew

    Exterior Trim (01.08) Body System (01.00) RH/LH Front Wheel Arch Liner-Renew 3. Install LH front wheel arch liner (see Workshop Manual procedure 01.02.FB Wheel Arch Liner - Front - LH - Repair Operation Time (ROT) Renew). Item Code Front Undertray-Renew Wheel Arch Liner-Renew 01.02.GB Repair Operation Time (ROT)

  • Page 30: Mirrors (01.09)

    Mirrors (01.09) Body System (01.00) Body System (01.00) Mirrors (01.09) 3. Turn on ignition and drive mirror to maximum away from door, turn off ignition and disconnect lucar Specifications connectors (x2). Installation Torque Figures 1. Connect lucar connectors to mirror glass (x2). Description 2.
  • Page 31 Mirrors (01.09) Body System (01.00) 1-6-2 Workshop Manual October 2005...

  • Page 32: Seating (01.10)

    Seating (01.10) Body System (01.00) Body System (01.00) Seating (01.10) Maintenance RH/LH Front Seat-Renew Description Repair Operation Time (ROT) The front seats are installed with the following features: Item Code • Integral side airbags Front Seat-Renew 01.10.AA • Head restraints Front Seat-Renew 01.10.AB •...
  • Page 33 Seating (01.10) Body System (01.00) 1-7-2 Workshop Manual October 2005...

  • Page 34: Glass, Frame And Mechanism (01.11)

    Glass, Frame and Mechanism (01.11) Body System (01.00) Body System (01.00) Glass, Frame and Mechanism (01.11) Description Installation 1. Install regulator mechanism and motor and secure with Power to the door window regulator motor is available when nuts (x4) and screws (x3). the ignition switch is at position ‘0’...

  • Page 35: Front Windshield-Renew

    Glass, Frame and Mechanism (01.11) Body System (01.00) 3. Remove inner handle trim and disconnect door latch 22. Install wiper arm passengers side (see Workshop Manual inner cable and remove securing bolts for the outer procedure 01.16.AE Arm Assembly - Wiper - Passenger cable.

  • Page 36: Instrument Panel (Ip) (01.12)

    Instrument Panel (IP) (01.12) Body System (01.00) Body System (01.00) Instrument Panel (IP) (01.12) 5. Remove tread plate badges - screws x2 (see Fig.1).  Specifications Torque Figures Description IP Mountings 22.5 Glue pot bolts Fig. 1 Blower motor to bulkhead 10-14 6.
  • Page 37 Instrument Panel (IP) (01.12) Body System (01.00) 8. Remove screw/release fir tree securing door seal plate to 13. Remove trim finishers (x4) and screws (x4) (see Fig. 5). 'A' post (see Fig. 3 and Fig. 4). Fig. 5 Fig. 3 14.
  • Page 38 Instrument Panel (IP) (01.12) Body System (01.00) 20. Pull back footwell carpets and remove bolts (x2) that secure instrument panel to tunnel (see Fig. 10). Fig. 8 17. Using special tool, release selector cable ball joints from Fig. 10 gear lever mechanism. 18.
  • Page 39 Instrument Panel (IP) (01.12) Body System (01.00) 24. Remove lower and upper column shrouds (see Fig. 13). 29. Remove instrument panel upper air vents x 2 (see Fig. 15). Fig. 13 Fig. 15 25. Release and remove drivers side lower instrument panel 30.
  • Page 40 Instrument Panel (IP) (01.12) Body System (01.00) 34. Manoeuvre and remove instrument panel sufficient to 7. Ensure instrument panel is correctly aligned and tighten gain access to heater hose (see Fig. 17). screws (x4) and bolts (x6) to correct torque. 8.

  • Page 41: Driver Upper Inner Panel Assembly-Renew

    Instrument Panel (IP) (01.12) Body System (01.00) Driver Upper Inner Panel Assembly- 1. Remove instrument cluster hood assembly (6 clips) Renew 2. Remove driver's upper outer panel assembly (4 clips) (see Fig. 1). Repair Operation Time (ROT) Item Code Driver Upper Inner Panel Assembly- 01.12.AC Renew Removal...

  • Page 42: Passenger Lower Panel Assembly-Renew9-7

    Instrument Panel (IP) (01.12) Body System (01.00) Driver Lower Panel Assembly-Renew 2. Remove passenger panel assembly (4 clips & 4 screws) See Fig. 1). Repair Operation Time (ROT) Item Code Driver Lower Panel Assembly-Renew 01.12.AH Removal 1. Remove driver's lower panel assembly (7 clips) and disconnect air temperature pipe (see Fig.

  • Page 43: Instrument Cluster Hood Assembly-Renew

    Instrument Panel (IP) (01.12) Body System (01.00) Installation 3. Remove the bolts (x3) that secure the airbag panel and door assembly plate to the chassis (see Fig. 2) 1. Install hood (6 clips). Glovebox Assembly-Renew Repair Operation Time (ROT) Item Code Glovebox Assembly-Renew...

  • Page 44: Glove Compartment Damper Spring-Renew

    Instrument Panel (IP) (01.12) Body System (01.00) Glovebox Shield-Renew 2. Remove driver's upper outer panel assembly (4 clips) (see Fig. 2). Repair Operation Time (ROT) Item Code Glovebox Shield-Renew 01.12.AP Removal 1. Remove glovebox (see Workshop Manual procedure 01.12.AL Glovebox Assembly - Renew).

  • Page 45: Driver Panel Assembly-Renew

    Instrument Panel (IP) (01.12) Body System (01.00) Driver Panel Assembly-Renew 3. Remove driver's upper inner panel assembly (5 clips) (see Fig. 3). Repair Operation Time (ROT) Item Code Driver Panel Assembly-Renew 01.12.AU Removal 1. Remove instrument panel hood assembly (6 clips) (see Fig.

  • Page 46: Glovebox Open Switch-Renew

    Instrument Panel (IP) (01.12) Body System (01.00) Master Lock Switch-Renew 2. Install instrument panel bezel assembly (see Workshop Manual procedure 01.12.AV Bezel Assembly - Repair Operation Time (ROT) Instrument Panel - Renew). Item Code Glovebox Open Switch-Renew Master Lock Switch-Renew 01.12.EA Repair Operation Time (ROT) Removal...
  • Page 47 Instrument Panel (IP) (01.12) Body System (01.00) 2. Remove PDC switch from panel. Installation 1. Install PDC switch to panel. 2. Install console panel assembly (see Workshop Manual procedure01.12.DB Panel Assembly Console - Renew). 1-9-12 Workshop Manual October 2005...

  • Page 48: Handles And Lock Mechanisms (01.14)

    Handles and Lock Mechanisms (01.14) Body System (01.00) Body System (01.00) Handles and Lock Mechanisms (01.14) Description Fuel Filler Assembly Vehicle Key/Remote Transmitter The vehicle key operates the ignition and the door lock, the remote transmitter operates the central locking and alarm systems. Do not leave them in the vehicle.

  • Page 49: Specifications

    Handles and Lock Mechanisms (01.14) Body System (01.00) Specifications 10. Install trimboard assembly (see Workshop Manual procedure 01.05.CB Trimboard Assembly - Door ­ Remove for Access & Refit). Torque Figures 0114BD|Latch Assembly - Hood - Renew Description Door handle Repair Operation Time Latch Item Code...

  • Page 50: Reduced Guard Switch-Renew

    Handles and Lock Mechanisms (01.14) Body System (01.00) Installation 4. Install tailgate trim panel (see Workshop Manual procedure 01.05.EF Trim - Tailgate Lid Assembly - 1. Clean door handle and mating face on door. Renew). 2. Install external door handle, install and torque tighten Passenger Window Lift Switch-Renew nuts (x3).
  • Page 51 Handles and Lock Mechanisms (01.14) Body System (01.00) 1-10-4 Workshop Manual October 2005...

  • Page 52: Wipers And Washer System (01.16)

    Wipers and Washer System (01.16) Body System (01.00) Body System (01.00) Wipers and Washer System (01.16) The wipers and washers system consists of the following The programmable wash and wipe sequence is driver components: controlled. With a depression of the wash/wipe switch between 40 milliseconds and 1.2 seconds the wash •...

  • Page 53: Specifications

    Wipers and Washer System (01.16) Body System (01.00) Specifications 9. Unclip wiper motor harness (x2) LHS. 10. Unclip windscreen heater harness RHS. Torque Figures 11. Disconnect motor multiplug and unclip harness (x2). Description Torque Figure (Nm) 12. To prevent damage, protect A/C pipe with tape before wiper linkage removal.

  • Page 54: Passenger Wiper Arm Assembly-Renew

    Wipers and Washer System (01.16) Body System (01.00) Passenger Wiper Arm Assembly-Renew 5. Clip headlamp washer pipe, connect pipe (quickfit) and multiplug. Repair Operation Time (ROT) 6. Connect windscreen washer motor multiplug. Item Code 7. Raise ramp. Passenger Wiper Arm Assembly-Renew 01.16.AE 8. Connect clip (x1) securing level sensor harness to reservoir.

  • Page 55: Headlamp Wash Motor And Pump Assembly-Renew11-4

    Wipers and Washer System (01.16) Body System (01.00) 2. Connect level sensor multiplug and manoeuvre reservoir 4. Install fixing screws (x3). into position. 5. Clip W/Washer pipe into reservoir and install to motor. 3. Connect filler pipe (clip x1). 6. Clip H/lamp washer pipe, connect pipe (quickfit) and 4. Install fixing screws (x3).
  • Page 56 Wipers and Washer System (01.16) Body System (01.00) 7. Clip W/Washer pipe into reservoir and install to motor. 8. Clip H/lamp washer pipe, connect pipe (quickfit) and multiplug. 9. Connect windscreen washer motor multiplug. 10. Raise ramp. 11. Connect clip (x1) securing level sensor harness to reservoir.
  • Page 57 Wipers and Washer System (01.16) Body System (01.00) 1-11-6 Workshop Manual October 2005...

  • Page 58: Bumpers (01.19)

    Bumpers (01.19) Body System (01.00) Body System (01.00) Bumpers (01.19) Front Bumper 6FUHZVWR)URQW:LQJ &OLS )URQW%XPSHU$VV\ &OLS  )URQW9DODQFH /RZHU0HVK Rear Bumper %XPSHU0RXQWLQJ %UDFNHWV %XPSHU$UPDWXUH ([KDXVW%UDFNHW DQG)LQLVKHU  October 2005 Workshop Manual 1-12-1...

  • Page 59: Specifications

    Bumpers (01.19) Body System (01.00) Specifications 3. Remove LH rear lamp assembly (see Workshop Manual procedure 17.03.AB Lamp Assembly (Rear) - LH Renew). Torque Figures 4. Remove RH rear lamp assembly (see Workshop Manual Description procedure 17.03.BB XREF: 280 Lamp Assembly (Rear) - Front Bumper to bumper bracket RH Renew).

  • Page 60: Rh/Lh Rear Lower Bumper Mesh-Renew

    Bumpers (01.19) Body System (01.00) RH/LH Rear Lower Bumper Mesh-Renew Repair Operation Time (ROT) Item Code Rear Lower Bumper Mesh 01.19.CA Rear Lower Bumper Mesh 01.19.CB Removal 1. Remove rear bumper (see Workshop Manual procedure 01.19.BA Cover Assembly - Rear Bumper - Renew). 2. Remove torx screws (x2) mesh to bumper armature.
  • Page 61 Bumpers (01.19) Body System (01.00) 1-12-4 Workshop Manual October 2005...

  • Page 62: Restraining Devices (01.20)

    Restraining Devices (01.20) Body System (01.00) Body System (01.00) Restraining Devices (01.20) Seat Belts    This vehicle is installed with two inertia reel safety belts. The In most moderate frontal or near frontal accidents, the front inertia belt reels automatically tension the belts to provide airbag and pre-tensioner systems will deploy simultaneously.

  • Page 63: Emergency Locking Retractor (Elr)

    Restraining Devices (01.20) Body System (01.00) mounted onto a spindle (torsion bar) which once the sensor has locked the retractor reel and a predetermined load is applied, twists and allows additional webbing into the system. The deceleration force required to initiate this sequence is approximately the same as that required to initiate airbag deployment.

  • Page 64: Airbag System

    Restraining Devices (01.20) Body System (01.00) Airbag System The airbag system is designed to provide increased collision No routine maintenance is required and there are no protection for front seat occupants in addition to that serviceable parts. The driver airbag module is replaced as an provided by the safety belt system.

  • Page 65: Maintenance

    Restraining Devices (01.20) Body System (01.00) Dual Inflation Technology 3. Rotate steering wheel to access and remove bolts (x2) from driver's airbag module to steering wheel (see Fig. When activated, the airbags will deploy at either a normal or reduced level of inflation, depending on crash severity. Various sensors determine the direction and severity of an impact.

  • Page 66: Side Impact Door Ars Sensor Assembly-Renew

    Restraining Devices (01.20) Body System (01.00) 2. Install airbag panel and door assembly (see Workshop Manual procedure 01.12.AJ Panel & Door Assembly - Air Bag - Renew). 3. Connect battery and reset codes. Side Impact Door ARS Sensor Assembly- Renew Repair Operation Time (ROT) Item Code...

  • Page 67: Frame And Mounting (02.00)

    Frame and Mounting (02.00) Contents Subframes (02.03) ..........2-1-2 Specifications............1-2 Maintenance ............1-2 Front Subframe-Renew .......... 1-2 Front Subframe-Remove/Refit ........ 1-4 Rear Subframe-Renew ........... 1-6 Rear Subframe-Remove/Refit ......... 1-7 RH/LH Transmission Rear Hydro mount Isolator Assembly-Renew ........1-10 RH/LH Engine Bracket-Renew......1-11 Engine Hydro mount Isolator Assembly-Renew ..

  • Page 68: Subframes (02.03)

    Subframes (02.03) Frame and Mounting (02.00) Frame and Mounting (02.00) Subframes (02.03) 14. Remove ride height sensor link nut and bolt from lower suspension arm (see Fig. 1). Specifications Torque Figures Description Ib/ft Subframe to Front Structure 105-125 77.5-92.5 Subframe to Body 105-125 77.5-92.5 Engine Mounts Steering Rack...
  • Page 69 Subframes (02.03) Frame and Mounting (02.00) 25. Remove engine mounting nuts (x2) (see Fig. 3). 30. Prepare support trolley 303-F715 with adaptors 303­ F715 051 to 4. 31. Position trolley, support subframe, remove bolts (x12) and raise vehicle (see Fig. 6). Fig.

  • Page 70: Front Subframe-Remove/Refit

    Subframes (02.03) Frame and Mounting (02.00) 20. Install ride height sensor link to lower suspension arm 13. Remove anti-roll bar links nuts (x2) and washers (x2). and tighten. 14. Remove nut and bolt from ride height sensor link to 21. Install and tighten nuts (x2) from track rod ends to lower suspension arm (see Fig.
  • Page 71 Subframes (02.03) Frame and Mounting (02.00) 26. Remove engine mounting nuts (x2) (see Fig 3). 31. Prepare support trolley 303-F715 with adaptors 303­ F715 051 to 4. 32. Position trolley, support subframe, remove bolts (x12)and raise vehicle. Fig. 3 27. Remove steering rack nuts (x3) from bolts (retain bolts in steering rack) (see Fig.

  • Page 72: Rear Subframe-Renew

    Subframes (02.03) Frame and Mounting (02.00) 21. Clean and Install brake discs and tighten Torx screws Attach slings to transaxle, connect suitable hoist and (x4). take weight of transaxle (see Fig. 2). 22. Install brake callipers and tighten Allen bolts (x4). 23.

  • Page 73: Rear Subframe-Remove/Refit

    Subframes (02.03) Frame and Mounting (02.00) 10. Remove bolts (x4) from anti-roll bar to subframe and 16. Install anti-roll bar and bolts (x4) (do not torque tighten remove anti-roll bar. at this stage). 11. Disconnect ABS sensor multiplugs (x2), release sensor 17.
  • Page 74 Subframes (02.03) Frame and Mounting (02.00) 16. Use tool 206-103 and release each handbrake cable 20. Release handbrake cable from clip and tie handbrake from mounting brackets. cable aside. 17. Release inner cable eyelets from calliper levers (see Fig. 21. Loosen and disconnect each brake pipe from body bracket and plug brake pipes (see Fig.
  • Page 75 Subframes (02.03) Frame and Mounting (02.00) 26. Loosen and disconnect unions (x2) from transaxle oil 30. Position subframe trolley (303-F715) under subframe cooler and plug pipe connections (see Fig. 6). (see Fig. 9).   Fig. 6 Fig. 9 27. Remove drain tray. 31.

  • Page 76: Rh/Lh Transmission Rear Hydro Mount Isolator Assembly-Renew

    Subframes (02.03) Frame and Mounting (02.00) 34. Using special tool 308-642, release selector cables (x2) 11. Position handbrake cables to subframe and install and from ball joints and remove horseshoe clips from tighten bolts (x4). selector cables to bracket (see Fig. 12). 12.

  • Page 77: Rh/Lh Engine Bracket-Renew

    Subframes (02.03) Frame and Mounting (02.00) 7. Remove nut from hydro mount to subframe (see Fig. 1). 10. Install cross brace and install and torque tighten bolts (x4). 11. Install rear exhaust silencer (see Workshop Manual procedure 09.00.KA Silencer and Bypass Valve Assembly - Remove for Access &...
  • Page 78 Subframes (02.03) Frame and Mounting (02.00) 5. Install engine mount lower fixing (nut x1) (torque). 6. Install RH/LH exhaust manifold (see Workshop Manual procedure 09.00.CA/09.00.CB - Exhaust Manifold - RH/ LH - Renew 2-1-12 Workshop Manual October 2005...
  • Page 79 Engine System (03.00) Contents Expansion Tank Assembly-Renew ......5-7 Engine Assembly (03.00) ........3-2-3 Description ............. 2-3 Coolant Recovery Tank Assembly-Renew....5-7 Maintenance ............2-4 Radiator Overflow Hose-Renew......5-7 Engine-Remove/Refit..........2-4 Radiator Supply-Tank to Radiator Hose-Renew..5-8 Engine Structure (03.01) ........3-3-1 Engine Coolant Reservoir Hose-Renew ....
  • Page 80 Coil Assembly-Engine Set-RH-Renew......9-1 RH Front Upper Heated Exhaust Gas Emission Control (03.08) ........3-10-1 Oxygen (HEGO) Sensor-Renew......16-2 Maintenance ............10-1 RH Rear Lower Heated Exhaust Gas Vacuum Outlet Hose Assembly-Renew ....10-1 Oxygen (HEGO) Sensor-Renew......16-3 Secondary Air Injection Pump Tube-Renew..10-1 Throttle Control (03.16)........3-17-1 Vacuum System Reservoir and Bracket Description ............17-1 Assembly-Renew ..........10-1...

  • Page 81: Engine Assembly (03.00)

    Engine Assembly (03.00) Engine (03.00) Engine (03.00) Engine Assembly (03.00) Description The engine is an all aluminium 4.3 litre 90° V8 configuration. The cylinder heads have dual overhead camshafts and four valves per cylinder. An electronic engine management system controls the sequential multi-port fuel injection and distributor-less ignition systems. The engine uses the latest ‘fast-burn’...

  • Page 82: Maintenance

    Engine Assembly (03.00) Engine (03.00) Maintenance Booster Hose Removal 27. Disconnect vacuum hose from booster. Engine-Remove/Refit P.A.S. Removal Repair Operation Time (ROT) 28. Remove oil rom reservoir (syringe). Item Code 29. Disconnect H.P. pipe from pump. Engine Remove and Install 03.00.AA 30.
  • Page 83 Engine Assembly (03.00) Engine (03.00) 62. Release harness from clips (x11) and position over Oil Tank Install engine. 21. Connect oil pipe from oil thermostat (torque). Purge Removal 22. Install oil tank (bolts x3) (torque). 63. Remove bottom screws (x2) and loosen top screw of 23.
  • Page 84 Engine Assembly (03.00) Engine (03.00) Suspension Install 86. Remove multiplugs (x10) from fusebox. 87. Remove earth terminal (1x nut &rubber cover) from 57. Install front springs and dampers (see Workshop Manual fusebox. procedure 04.03.AA Spring & Damper Assembly - Front Pair - Renew).
  • Page 85 Engine Assembly (03.00) Engine (03.00) 122.Remove gaskets and clean mating faces. Installation LH Side Removal Manifold Parts 161.Connect breather hose to manifold (quickfit). 123.Remove EGR valve (bolts x2) and gasket. 162.Connect IAT multiplug. 124.Remove IAT sensor. 163.Unclip injector harness from cam cover (x2). 125.Remove throttle body (bolts x4) and gasket.
  • Page 86 Engine Assembly (03.00) Engine (03.00) 193.Release fuel feed hose from rail (clip x1) & move aside. 228.Connect EGR vacuum hose. 194.Disconnect heater hose from pipe (quick fit). 229.Connect air cleaner duct (clip x1). 195.Release heater hose (clips x2) and EGR vacuum line 230.Connect breather pipe quickfits (x2) to air cleaner duct.
  • Page 87 Engine Assembly (03.00) Engine (03.00) 267.Install cross brace. (torque bolts with vehicle on level ground). October 2005 Workshop Manual 3-1-9...
  • Page 88 Engine Assembly (03.00) Engine (03.00) 3-1-10 Workshop Manual October 2005...

  • Page 89: Engine Structure (03.01)

    Engine Structure (03.01) Engine (03.00) Engine Structure (03.01) Description Engine Block The 4.2L engine consists of an eight cylinder 90 degree 'Enclosed V' configuration liquid cooled aluminium cylinder block with dry cast liners. Viewed from the driving position, the right-hand cylinder bank is designated A-bank and the left-hand cylinder bank as B- bank.

  • Page 90: Knock Sensors

    Engine Structure (03.01) Knock Sensors Bedplate Two knock sensors are fitted to the cylinder block on the This is a structural casting bolted to the bottom of the inboard side of each cylinder bank. The electrical connector cylinder block to retain the crankshaft and to further of each sensor is secured to the left-hand engine cover improve overall rigidity.
  • Page 91 Engine Structure (03.01) Cylinder Heads Inlet/Exhaust Manifolds Intake air is filtered and passed through mass air flow meters (MAF). The air then passes through the throttle bodies into the six branch inlet manifolds. E 43444 Item Description Item Description Camshaft bearing cap Valve stem oil seal Tappet (No Shim) Valve...

  • Page 92: Cylinder Heads

    Engine Structure (03.01) Specifications 15. Remove purge pipe p-clip (bolt x1) and move pipe aside. 16. Remove harness bracket from engine (bolts x2, nut x1). Engine Block Dimension (mm) Cylinder Bore Grade 17. Release fuel feed hose from rail (clip x1) & move aside. Main Bearing Bore (without shells) 18.
  • Page 93 Engine Structure (03.01) Installation 40. Install harness support bracket (bolt x1, nut x2) release harness clips (fir tree x3). 1. Install fuel rail (bolts x4) with injectors. (fit new o-rings to 41. Connect booster hose to manifold and support clip. injectors).
  • Page 94 Engine Structure (03.01) 3-2-6 Workshop Manual October 2005...

  • Page 95: Lubrication System (03.02)

    Lubrication System (03.02) Engine (03.00) Engine (03.00) Lubrication System (03.02) Dry Sump System Unlike a wet sump system where oil is stored in the sump, a The primary advantage of a dry sump system is its ability to dry sump oiling system stores oil in a separate tank, leaving make more power.

  • Page 96: Specifications

    Lubrication System (03.02) Engine (03.00) Specifications Maintenance Oil Filter-Renew Engine oil Europe/Aus Castrol Formula RS 10W-60 Repair Operation Time (ROT) Item Code To achieve the required high performance of synthetic lubricants, do not mix with mineral oils. Oil Filter-Renew RHD 03.02.AA Oil Filter-Renew LHD 03.02.AB Capacity...
  • Page 97 Lubrication System (03.02) Engine (03.00) 3. Clean off excess oil. 4. Remove container. 5. Lower vehicle on ramp. 6. Fill tank with approximately amount of displaced oil and replace cap. 7. Use handbook procedure to check oil level. October 2005 Workshop Manual 3-3-3...
  • Page 98 Lubrication System (03.02) Engine (03.00) 3-3-4 Workshop Manual October 2005...

  • Page 99: Cooling System (03.03)

    Cooling System (03.03) Engine (03.00) Engine (03.00) Cooling System (03.03) Description • Water pump • Coolant Reservoir • Thermostat • Electric cooling fans (x2) • Radiator • Cooling fan motor control module • Pressure cap • Engine oil cooler Water Pump and returns to the water pump through the lower coolant hose and water cross-over housing.

  • Page 100: Engine Oil Cooler

    Cooling System (03.03) Engine (03.00) Maintenance The coolant reservoir should be full when the coolant system is cold. Engine Oil Cooler Caution ‘Spring band’ clips The oil temperature is controlled by an air/oil cooler ‘Spring band’ clips must be installed as detailed below: mounted at the front of the car.

  • Page 101: Radiator Assembly-Renew

    Cooling System (03.03) Engine (03.00) Radiator Assembly-Renew 3. Disconnect fan multiplugs (x2). 4. Remove nuts (x2) securing fans to radiator. Repair Operation Time (ROT) 5. Remove fan assembly (unclip from radiator). Item Code Installation Radiator Assembly-Renew 03.03.EB 1. Install fan assembly (clip to radiator). Removal 2.

  • Page 102: Engine Coolant Reservoir Hose-Renew

    Cooling System (03.03) Engine (03.00) Installation Water Pump Pulley-Renew 1. Install thermostat and sealing ring. Repair Operation Time (ROT) 2. Install thermostat housing (torque). Item Code 3. Install breather valve bracket. Water Pump Pulley-Renew 03.03.CE 4. Install breather hoses (x3) and clip. Removal 5.

  • Page 103: Oil Cooler Tank Pipe Assembly-Renew

    Cooling System (03.03) Engine (03.00) 4. Disconnect top hose from engine (clip x1) tie aside 4. Install RH air filter box (see Workshop Manual (catch coolant). procedure 03.12.BB Air Filter Box RH Renew). 5. Remove breather pipe (quick fit). 5. Lower vehicle on ramp. 6.

  • Page 104: Oil Pump Outlet Tube Assembly-Renew

    Cooling System (03.03) Engine (03.00) Oil Thermostat Cooler Pipe Assembly- 6. Remove bolts securing oil pipes to block. Renew 7. Release both pipes from block and remove inlet pipe. Installation Repair Operation Time (ROT) 1. Renew o-ring on remaining oil pipe. Item Code 2.

  • Page 105: Throttle Heating Feed Hose-Renew

    Cooling System (03.03) Engine (03.00) 6. Lower vehicle on ramp. 2. Install nut and bolt, tighten to correct torque. Throttle Heating Feed Hose-Renew 3. Install hoses (x3) on expansion tank, secure with clips (x3). Repair Operation Time (ROT) 4. Install LH cross brace, install bolts (x4) (torque with Item Code vehicle on level ground).

  • Page 106: Radiator Supply-Tank To Radiator Hose-Renew

    Cooling System (03.03) Engine (03.00) Radiator Supply-Tank to Radiator Hose- 2. Install hose in body clips (x2). Renew 3. Install wheel arch liner (see Workshop Manual procedure 01.02.FB Wheel Arch Liner - Front - LH - Repair Operation Time (ROT) Renew).

  • Page 107: Heater Feed Hose-Renew

    Cooling System (03.03) Engine (03.00) Heater Feed Hose-Renew 3. Release hose from bulkhead clip and feed from behind inlet manifold. Repair Operation Time (ROT) Installation Item Code 1. Install hose behind inlet manifold and into bulkhead Heater Feed Hose-Renew 03.03.LA clip.

  • Page 108: Rh/Lh Cooling Fan Motor-Renew

    Cooling System (03.03) Engine (03.00) Engine Electric Coolant Temperature 6. Disconnect heater return hose (clip x1). Sensor-Renew 7. Disconnect breather hose (quickfit). 8. Disconnect separator hose (clip x1). Repair Operation Time (ROT) 9. Disconnect coolant temp multiplug. Item Code 10. Remove harness clips (x2). Engine Electric Coolant Temperature 03.03.GB 11.

  • Page 109: Fuel Charging System (03.04)

    Fuel Charging System (03.04) Engine (03.00) Fuel Charging System (03.04) Safety Precautions Operations on fuel system result 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: Warning Operations on refuelling and the fuel system must only be...

  • Page 110: Maintenance

    Fuel Charging System (03.04) Maintenance 29. Release heater hose (x2) and throttle body hose (x2) from support bracket. Fuel Rails-Renew 30. Remove booster hose from manifold (V/difficult) and support clip. Repair Operation Time (ROT) 31. Remove harness support bracket (bolt x1, nut x2) Item Code release harness clips (fir tree x3).

  • Page 111: Fuel Injection Pressure Sensor-Renew

    Fuel Charging System (03.04) Installation 18. Refit heater hose (clipx2) and EGR vacuum lines (clips x2) to bracket. 1. Install sensor to fuel rail (bolts x2) (torque). 19. Install fuel feed pipe. 2. Connect multiplug. 20. Install purge pipe p-clip. 3.

  • Page 112: Fuel Injector-Each-Lh Bank-Renew

    Fuel Charging System (03.04) Removal 17. Release heater hose (clips x2) and EGR vacuum line (clips x2) from bracket. 1. Depressurise fuel rail (see Workshop Manual procedure 18. Release harness from coolant pipe bracket (fir tree x3). 10.01.EK Fuel System - Depressurise). 19.

  • Page 113: Fuel Injector-Each-Rh Bank-Renew

    Fuel Charging System (03.04) Fuel Injector-Each-RH Bank-Renew 8. Connect heater hose to pipe (quick fit). 9. Refit heater hose (clipx2) and EGR vacuum lines (clips Repair Operation Time (ROT) x2) to bracket. Item Code 10. Install fuel feed pipe. Fuel Injector-Each-RH Bank-Renew 03.03.GF 11.

  • Page 114: Engine Set-Fuel Injector-Rh Bank-Renew

    Fuel Charging System (03.04) Installation 14. Remove harness bracket from engine (bolts x2, nut x1). 15. Release fuel feed hose from rail (clip x1) & move aside. 1. Install clips on to new injectors then fit injectors into 16. Disconnect heater hose from pipe (quick fit). manifold.

  • Page 115: Throttle Body-Renew

    Fuel Charging System (03.04) Throttle Body-Renew Repair Operation Time (ROT) Item Code Throttle Body-Renew 03.04.HA Removal 1. Remove duct from throttle body (clip x1). 2. Disconnect breather hoses (x2) for access. 3. Disconnect multiplug and harness from clip. 4. Remove throttle body and gasket (bolts x4). Installation 1.
  • Page 116 Fuel Charging System (03.04) 3-5-8 Workshop Manual October 2005...

  • Page 117: Accessory Drive System (03.05)

    Accessory Drive System (03.05) Engine (03.00) Accessory Drive System (03.05) Maintenance Drive Belt-Renew Description Repair Operation Time (ROT) Item Code Drive Belt-Renew 03.05.AB Removal 1. Remove throttle body duct for access. (clips x3). 2. Disconnect breather pipe quickfits (x2) from air cleaner duct.

  • Page 118: Engine Drive Belt Idle Assembly-Renew

    Accessory Drive System (03.05) Installation 1. Install idler to engine (bolt x1) (torque). 2. Release tensioner and slip belt on idler. 3. Install throttle body duct. 4. Connect breather pipe quickfits (x2) to air cleaner duct. Engine Drive Belt Idle Assembly-Renew Repair Operation Time (ROT) Item Code...

  • Page 119: Engine Cranking System (03.06)

    Engine Cranking System (03.06) Engine (03.00) Engine Cranking System (03.06) 4. Switch battery isolation switch ‘ON’. 5. Install RH exhaust manifold (see Workshop Manual Starting System procedure 09.00.CA Manifold - Exhaust - RH - Renew). Starter Button-Renew Maintenance Starter Motor-Renew Repair Operation Time (ROT) Item Code...
  • Page 120 Engine Cranking System (03.06) 3-7-2 Workshop Manual October 2005...

  • Page 121: Ignition System (03.07)

    Ignition System (03.07) Engine (03.00) Spark Plugs-LH Bank-Renew Engine (03.00) Ignition System (03.07) Repair Operation Time (ROT) Maintenance Item Code Spark Plugs-LH Bank-Renew 03.07.EB RH/LH Ignition Coil Assembly-Renew 1. Remove coils (see Workshop Manual procedure 03.07.GB Coil Assembly - Engine Set - LH - Renew). Repair Operation Time (ROT) 2.
  • Page 122 Ignition System (03.07) Engine (03.00) 3-8-2 Workshop Manual October 2005...

  • Page 123: Emission Control (03.08)

    Emission Control (03.08) Engine (03.00) Engine (03.00) Emission Control (03.08) Maintenance 2. Disconnect vacuum hose from reservoir. 3. Unclip harness from bracket. Vacuum Outlet Hose Assembly-Renew 4. Remove reservoir (bolts x3). Installation Repair Operation Time (ROT) Item Code 1. Install reservoir (bolts x3) (torque). Vacuum Outlet Hose Assembly-Renew 03.08.AC 2.

  • Page 124: Emissions Separator Hose-Renew

    Emission Control (03.08) Engine (03.00) 6. Disconnect hose from engine (quickfit) and remove 2. Remove inlet manifold assembly (see Workshop Manual hose. procedure 03.01.BA Manifold Assembly - Intake Upper - Renew). Installation 3. Disconnect breather tube to secondary air pump 1.

  • Page 125: Exhaust Valve To Exhaust Manifold Tube Assembly-Renew

    Emission Control (03.08) Engine (03.00) 2. Disconnect hose from oil separator (quickfit) and 2. Loosen and disconnect pipe union, EGR module to remove. exhaust manifold. Installation 3. Remove bolts (x2) securing EGR module to inlet manifold, remove EGR module, discard gasket. 1.
  • Page 126 Emission Control (03.08) Engine (03.00) 3-9-4 Workshop Manual October 2005...

  • Page 127: Valve Train (03.09)

    Valve Train (03.09) Engine (03.00) Engine (03.00) Valve Train (03.09) Maintenance RH/LH Cam Timing Sensor-Renew Repair Operation Time (ROT) Item Code Cam Timing Sensor-Renew 03.01.HJ Cam Timing Sensor-Renew 03.01.HK Removal 1. Remove inlet manifold (see Workshop Manual procedure 03.01.BB Gasket - Manifold Assembly - Intake Upper - Renew).
  • Page 128 Valve Train (03.09) Engine (03.00) 3-10-2 Workshop Manual October 2005...

  • Page 129: Engine Sealing (03.10)

    Engine Sealing (03.10) Engine (03.00) Engine (03.00) Engine Sealing (03.10) 4. Connect IAT multiplug. 5. Unclip injector harness from cam cover (x2). Specifications 6. Connect injector multiplugs (x4). 7. Install pipe support bracket (nuts x2, bolts x2). Torque Figures 8. Install harness support bracket (bolt x1, nut x2) release Description lb./ft.

  • Page 130: Lh Cylinder Head Cover Gasket-Renew

    Engine Sealing (03.10) Engine (03.00) 22. Disconnect heater hose from pipe (quick fit). 5. Disconnect heater hose from pipe (quick fit). 23. Release heater hose (clips x2) and EGR vacuum line 6. Release heater hose (x2) and throttle body hose (x2) (clips x2) from bracket.

  • Page 131: Rh/Lh Ignition Coil Cover-Renew

    Engine Sealing (03.10) Engine (03.00) Under Bonnet 15. Install battery lead to fusebox (1x nut &rubber cover). 16. Install multiplugs to fuse box. 8. Remove coils (see Workshop Manual procedure 03.07.HC XREF: 398 Coil Assembly - Engine Set - RH - 17.
  • Page 132 Engine Sealing (03.10) Engine (03.00) 3-11-4 Workshop Manual October 2005...

  • Page 133: Power Conversion (03.11)

    Power Conversion (03.11) Engine (03.00) Engine (03.00) Power Conversion (03.11) Maintenance Crankshaft Timing Sensor-Renew Repair Operation Time (ROT) Item Code Crankshaft Timing Sensor-Renew 03.02.AR Removal 1. Raise vehicle on ramp. 2. Disconnect cranksensor multiplug. 3. Remove sensor (bolt x1). Installation 1.
  • Page 134 Power Conversion (03.11) Engine (03.00) 3-12-2 Workshop Manual October 2005...

  • Page 135: Air Charging (03.12)

    Air Charging (03.12) Engine (03.00) Engine (03.00) Air Charging (03.12) RH/LH Mass Airflow Assembly Sensor- Renew Maintenance Repair Operation Time (ROT) RH/LH Air Filter Box-Renew Item Code Mass Airflow Assembly Sensor-Renew 03.12.EB Repair Operation Time (ROT) Mass Airflow Assembly Sensor-Renew 03.12.FB Item Code...
  • Page 136 Air Charging (03.12) Engine (03.00) 3-13-2 Workshop Manual October 2005...

  • Page 137: Evaporative Emissions (03.13)

    Evaporative Emissions (03.13) Engine (03.00) Engine (03.00) Evaporative Emissions (03.13) System Operation Displaced fuel vapour leaves the fuel tank via the normally Description open fill level vent valve and the roll over valves. It passes The evaporative loss system prevents escape of fuel vapours through the carbon canister where fuel hydrocarbons are into the atmosphere.

  • Page 138: Fuel Vapour To Manifold Tube-Renew

    Evaporative Emissions (03.13) Engine (03.00) 2. Connect pipe to tank pipe (quickfit). 4. Install LH rear wheel arch liner (see Workshop Manual procedure 01.02.JB Wheel Arch Liner - Rear - LH - 3. Connect pipe (x1) to valve (quickfit). Renew). 4.

  • Page 139: Engine Management System (03.14)

    Engine Management System (03.14) Engine (03.00) Engine (03.00) Engine Management System (03.14) Maintenance 7. Lower vehicle. 8. Connect battery. Engine Temperature Spark Plug Knock 9. WDS Operation check (see Workshop Manual Sensor-Renew procedure 00.06.AD WDS Operation - Check). LH Front Lower Heated Exhaust Gas Repair Operation Time (ROT) Oxygen (HEGO) Sensor-Renew Item...

  • Page 140: Lh Front Upper Heated Exhaust Gas Oxygen (Hego) Sensor-Renew

    Engine Management System (03.14) Engine (03.00) LH Front Upper Heated Exhaust Gas RH Front Upper Heated Exhaust Gas Oxygen (HEGO) Sensor-Renew Oxygen (HEGO) Sensor-Renew Repair Operation Time (ROT) Repair Operation Time (ROT) Item Code Item Code Front Upper Heated Exhaust Gas 03.14.EB Front Upper Heated Exhaust Gas 03.14.GB...
  • Page 141 Engine Management System (03.14) Engine (03.00) RH Rear Lower Heated Exhaust Gas Oxygen (HEGO) Sensor-Renew Repair Operation Time (ROT) Item Code Rear Lower Heated Exhaust Gas 03.14.JB Oxygen (HEGO) Sensor-Renew Removal 1. Raise vehicle on ramp. 2. Remove rear exhaust silencer (see Workshop Manual procedure 09.00.KA Silencer and Bypass Valve Assembly - Remove for Access &...
  • Page 142 Engine Management System (03.14) Engine (03.00) 3-15-4 Workshop Manual October 2005...

  • Page 143: Throttle Control (03.16)

    Throttle Control (03.16) Engine (03.00) Engine (03.00) Throttle Control (03.16) Description Motorised Throttles The motorised throttle allows accurate control of the inlet air. A throttle position sensor (TPS) is incorporated into the throttle unit. During normal engine run, TPS signals are used by the PCM to indicate power demand from the engine.
  • Page 144 Throttle Control (03.16) Engine (03.00) 3-16-2 Workshop Manual October 2005...
  • Page 145 Foot Operated Control (03.18) Engine System (03.00) Engine System (03.00) Foot Operated Control (03.18) Maintenance Throttle Pedal Assembly-Renew Repair Operation Time (ROT) Item Code Throttle Pedal Assembly-Renew 03.18.AC Removal 1. Remove drivers seat (see Workshop Manual procedure 01.10.AB Seat Assembly - Front - LH - Remove for Access &...

  • Page 146: Suspension (04.00)

    Suspension (04.00) Contents Tread Wear ............5-2 Road Wheel Alignment (04.00) ......4-1-2 Specifications ............1-2 Traction ..............5-2 Maintenance ............1-2 Temperature............5-2 Caster Angle ............1-3 Maintenance............5-2 Camber Angle............1-3 Safety ..............5-2 Toe................ 1-3 Tyre Replacement and Wheel Interchanging ..5-3 Front Suspension (04.01)........4-2-1 Winter (Snow) tyres..........

  • Page 147: Road Wheel Alignment (04.00)

    Road Wheel Alignment (04.00) Suspension (04.00) Suspension (04.00) Road Wheel Alignment (04.00) Maintenance Specifications Repair Operation Time (ROT) Item Code Front Rear All Wheel Alignment 04.00.AD 3’ (±2’) 10’ (+5’/-0’) Refer to the geometry setup tool manufacture operating (individual) instructions. Total Toe 6’...

  • Page 148: Front Suspension (04.01)

    Front Suspension (04.01) Suspension (04.00) Suspension (04.00) Front Suspension (04.01) Description Specifications Suspension Arms Torque Figures The upper suspension arm is attached to the body structure. Description lb. / ft. The lower suspension arm is attached to the front subframe. Brake dust shield.

  • Page 149: Symptoms

    Front Suspension (04.01) Suspension (04.00) Symptoms Symptom Possible Cause Action Crabbing Front or rear suspension components/road Inspect front and rear suspension systems. wheel alignment Check / adjust road wheel alignment Drive axle damaged New drive axle. Front ‘Bottoming’ Spring(s) Check ride height. or Riding Low Dampers Check dampers.

  • Page 150: Maintenance

    Front Suspension (04.01) Suspension (04.00) Symptom Possible Cause Action Vibration/Noise Tyres/road wheel Check. Install new components as required. Road wheel bearing assemblies Brake components Suspension components Spring and damper units Steering components Vehicle Leans to Unevenly loaded or overloaded vehicle Notify customer of incorrect vehicle loading.

  • Page 151: Front-Renew

    Front Suspension (04.01) Suspension (04.00) 4. Remove nut/bolt securing damper to lower suspension 6. Remove nuts (x3), damper top mounting. Remove arm, release damper from mounting. engine cross brace support. 5. Remove nut securing lower suspension arm ball joint to 7.
  • Page 152 Front Suspension (04.01) Suspension (04.00) Installation 4. Install drop links to anti-roll bar, install nuts/washers (x2). Do not torque tighten. 1. Clean anti-roll bar link and mating faces on lower 5. Final tightening of suspension components must be suspension arm and anti-roll bar. carried out with the suspension arms at normal ride 2.

  • Page 153: Front Suspension Sensor Assembly-Renew

    Front Suspension (04.01) Suspension (04.00) 4. Install vertical link assembly to upper suspension arm. 5. Lower vehicle on ramp. Install and torque tighten nut. 5. Install vertical link in lower suspension arm. Install and torque tighten nut. 6. Clean brake disc. 7.

  • Page 154: Rear Suspension (04.02)

    Rear Suspension (04.02) Suspension (04.00) Suspension (04.00) Rear Suspension (04.02) Description Suspension Arms Vertical Link The upper suspension arms are each installed with a press- The vertical link carries the hub, the cartridge wheel bearing, fit ball joint, and two interleaved rubber bushes. Two bolts the ABS rotor, the wheel speed sensor, the brake caliper, the attach each upper suspension arm to the rear subframe.

  • Page 155: Specifications

    Rear Suspension (04.02) Suspension (04.00) Specifications 6. Remove handbrake calliper bolts (x2) and tie calliper aside. 7. Remove brake disc Torx screws (x2), remove disc. Torque Figures 8. Remove Allen bolts (x4) securing hub bearing assembly Description lb. / ft. in vertical link.
  • Page 156 Rear Suspension (04.02) Suspension (04.00) Installation 7. Install road wheel(s). 8. Lower vehicle on ramp. 1. Clean toe control arm and mating faces on vertical link 9. Torque tighten suspension nuts/bolts. and subframe. 10. 4 wheel alignment - check/adjust (see Workshop 2.
  • Page 157 Rear Suspension (04.02) Suspension (04.00) Rear Pair-Anti-Roll Bar Bushing-Renew RH/LH Rear Hub Vertical Link-Renew Repair Operation Time (ROT) Repair Operation Time (ROT) Item Code Item Code Rear Anti-Roll Bar Bushing-Renew 04.02.BC Rear Hub Vertical Link-Renew 04.02.HB Rear Hub Vertical Link-Renew 04.02.GB Removal Removal...

  • Page 158: Rear Suspensions Sensor Assembly-Renew

    Rear Suspension (04.02) Suspension (04.00) 13. Install ABS sensor multiplug. 14. Install toe rod to vertical link, install bolt/nut. Do not torque tighten at this stage. 15. Install road wheel/s 16. Pump brake pedal. 17. Lower vehicle on ramp. 18. With assistance, torque tighten rear hub nut. 19.
  • Page 159 Rear Suspension (04.02) Suspension (04.00) 4-3-6 Workshop Manual October 2005...

  • Page 160: Shock Absorber System (04.03)

    Shock Absorber System (04.03) Suspension (04.00) Suspension (04.00) Shock Absorber System (04.03) 3. Disconnect ABS sensor multiplug (see Fig. 1). Description Movement of each road spring is independently damped by a telescopic, hydraulically-controlled shock absorber. Each shock absorber is installed coaxially within the road spring. Front spring and damper assemblies are located between the upper suspension arm and attach to the lower suspension arm and the body structure.
  • Page 161 Shock Absorber System (04.03) Suspension (04.00) 7. Position suspension arm aside (see Fig. 4). 10. Remove spring and damper assembly. Installation 1. Install spring and damper assembly and engine cross brace support. 2. Install top mounting nuts (x3) each side (do not torque tighten).
  • Page 162 Shock Absorber System (04.03) Suspension (04.00) 4. Release sensor harness clips (x3) from upper suspension 8. Remove nuts (x3 each side) from damper top mounting arm and vertical link (see Fig. 2). and remove engine cross brace support (see Fig. 5). Fig.
  • Page 163 Shock Absorber System (04.03) Suspension (04.00) 6. Install top mounting nuts (x3) each side (do not torque 6. Install top mounting nuts (x3) each side (do not torque tighten). tighten). 7. Align damper to lower mounting and install bolts and 7.
  • Page 164 Shock Absorber System (04.03) Suspension (04.00) 8. Disconnect ABS sensor multiplug (see Fig. 2). 11. Remove nuts and bolts both sides from toe control arms (see Fig. 5). Fig. 2 9. Release sensor harness clips (x2) from toe control arm (see Fig.
  • Page 165 Shock Absorber System (04.03) Suspension (04.00) 13. Remove bolts (x4) each side from damper upper 2. Install spring and damper assembly and torque tighten mounting (see Fig. 7). upper bolts (x4) each side. 3. Install damper to lower arm each side and torque tighten nuts and bolts.
  • Page 166 Shock Absorber System (04.03) Suspension (04.00) 7. Remove nut securing fuel filler pipe to body and tie filler 10. Remove bolts (x2) each side from handbrake calliper to pipe aside (see Fig. 1). rear hub and release calliper and position aside (see Fig. Fig.
  • Page 167 Shock Absorber System (04.03) Suspension (04.00) 12. Remove nuts and bolts each side from lower damper Fig. 8 mountings (see Fig. 6). 15. Remove nuts (x3) each side from damper to mounting plates and remove mounting plates (see Fig. 9). Fig.
  • Page 168 Shock Absorber System (04.03) Suspension (04.00) Rear Damper-Pair-Renew 8. Position fuel filler pipe to body and install and tighten nut. Repair Operation Time (ROT) 9. Position fuel filler pipe and install and tighten bolt. Item Code 10. Position toe control arm each side and install and torque Rear Damper-Pair-Renew 04.03.BC tighten nuts and bolts.
  • Page 169 Shock Absorber System (04.03) Suspension (04.00) 4-4-10 Workshop Manual October 2005...

  • Page 170: Road Wheels And Tyres (04.04)

    Specifications Tyres Warning The tyres recommended by Aston Martin meet the high Do not mix different types of tyres on the same vehicle speed performance of this vehicle. Only tyres of identical such as radial, bias or bias belted tyres except in specification may be installed as replacements.

  • Page 171: Usa Tyre Gradings

    When changing a wheel, make sure that the vehicle separately or in combination, can cause heat build-up cannot move. Always apply the parking brake and and possible tyre failure. select the transmission park position (Automatic Aston Martin grade as follows: transmission only). Tyre Grade Level Achieved Warning...

  • Page 172: Tyre Replacement And Wheel Interchanging

    • Snow chains must only be installed to the rear wheels Tyre tread depth and condition must comply with • Only Aston Martin snow chains should be used prevailing local legislation. • Snow chains must not be used on roads which are clear of...
  • Page 173 Road Wheels and Tyres (04.04) Suspension (04.00) Road Test A tyre vibration diagnostic procedure always begins with a road test. The road test and customer interview (if available) will provide much of the information needed to find the source of a vibration. During the road test, drive the vehicle on a road that is smooth and free of undulations.

  • Page 174: Tyre Damage

    Road Wheels and Tyres (04.04) Suspension (04.00) Symptom Possible Source(s): Action(s) Vehicle vibrations Tyres and wheels mismatched Install correct tyre and wheel combination. Inflation pressure too high or too low Correct pressure to specification Uneven tyre wear Refer to Diagnosis and Testing. Out-of-balance wheel, tyre, wheel hub Determine the out-of-balance component and or disc assembly...

  • Page 175: Repairs

    Road Wheels and Tyres (04.04) Suspension (04.00) Repairs In view of the high performance capability of the vehicle, damaged tyres should be renewed and not repaired. Caution When a new tyre is installed, always renew the tyre valve. Care of Alloy Road Wheels Aluminium alloy road wheels are covered with a protective coating.

  • Page 176: Road Wheel And Tyre Balance

    Road Wheels and Tyres (04.04) Suspension (04.00) Misalignment Effects Dynamic imbalance of the tyre and road wheel assemblies can be measured on suitable tyre balancing equipment, and Misalignment Effect corrections implemented. Where it is clear that a damaged Road wheels are correctly aligned All tyres will wear road wheel is the primary cause of severe imbalance, it is but crabbing due to road camber...

  • Page 177: Tyre Pressure Sensing (Option)

    Road Wheels and Tyres (04.04) Suspension (04.00) Tyre Pressure Sensing (Option) Warnings Instrument Lamp constant / Message ‘Check Tyres’. Warning Cluster Tyre pressure sensing is not intended to replace driver Control module Tyre LED constant red. awareness of tyre performance or the need for Fault Tyre pressure below specification.

  • Page 178: Display Unit

    Road Wheels and Tyres (04.04) Suspension (04.00) Display Unit 4. If any tyre pressure sensor is defective, the display will show three dashes to indicate the absence of data for The display unit provides additional features when correctly that tyre. connected to a previously installed ‘Smartire’...
  • Page 179 Road Wheels and Tyres (04.04) Suspension (04.00) Tyre Rotation 5. Press ‘Set’ to enter the new value into memory. Pressure Deviation Alert Warning The road wheels and tyres are asymmetrical and different sizes front and rear. They must not be rotated front to rear.
  • Page 180 Road Wheels and Tyres (04.04) Suspension (04.00) 2. Press ‘Mode’ until pressure / temperature units are 2. Add new Transmitters. displayed. Press ‘Set’ for 5 seconds to enter level 2 3. Press ‘Tyre’ to enter ‘Units Selection’ mode. programming. 4. Use ‘Tyre’ or ‘Mode’ to scroll through four combinations Press ‘Mode’...

  • Page 181: Driveline (05.00)

    Driveline (05.00) Contents Driveshaft (05.01)..........5-1-2 Description ............. 1-2 Specifications............1-2 Maintenance ............1-2 Torque Tube-Remove for Access/Refit....1-2 RH/LH Drive Shaft Assembly-Renew ...... 1-4 Halfshafts (05.05) ..........5-2-1 Specifications............2-1 October 2005 Workshop Manual 5-1-1...

  • Page 182: Driveshaft (05.01)

    Driveshaft (05.01) Driveline (05.00) Driveline (05.00) Driveshaft (05.01) Description The driveshaft consists of a torque tube assembly, incorporating a carbon fibre propshaft, transferring engine power to the gearbox. The torque tube acts as a structural support between the engine and transmission through the powertrain maintaining NVH (Noise, Vibration &...
  • Page 183 Driveshaft (05.01) Driveline (05.00) 12. Remove large circlip using special tool (see Fig. 1). 14. Open clutch hydraulics bleed nipple and with suitable container below, press clutch pedal fully and retain pedal in that position. Tighten bleed nipple (see Fig. 3). Fig.

  • Page 184: Rh/Lh Drive Shaft Assembly-Renew

    Driveshaft (05.01) Driveline (05.00) 17. Remove torque tube (see Fig. 6) 4. Clean and install plates (x3), Allen bolts (x6), tighten bolts. 5. Install drive shaft nut. With assistance, tighten nut. 6. Install rear undertray (see Workshop Manual procedure 01.02.PB Undertray - Rear - Renew). 7.

  • Page 185: Halfshafts (05.05)

    Halfshafts (05.05) Driveline (05.00) Driveline (05.00) Halfshafts (05.05) Specifications Torque Figures Description lb/ft Halfshaft nut 221.5 Halfshaft to differential October 2005 Workshop Manual 5-2-1...
  • Page 186 Brake System (06.00) Contents Yaw Rate Sensor-Renew ........6-4 Front Disc Brake (06.03)........6-1-2 Description ............. 1-2 Specifications............1-2 Maintenance ............1-3 RH/LH Shield Assembly-Front Brake Disc-Renew ... 1-3 Brake Disc Set-Front-Renew........1-3 Brake Pads-Front-Renew........1-3 RH/LH Front Brake Calliper-Renew......1-3 Brake Pad ‘Bedding-in’...

  • Page 187: Brake System (06.00)

    Front Disc Brake (06.03) Brake Systems (06.00) Brake Systems (06.00) Front Disc Brake (06.03) Description Brake pads The front, four piston, brake caliper is bolted directly to the New pad thickness 9.4 mm vertical link by two bolts. The caliper is a monobloc assembly.

  • Page 188: Maintenance

    Front Disc Brake (06.03) Brake Systems (06.00) Maintenance 2. Install new calliper and secure bolts (x2) (torque). 3. Apply anti-seize compound to pads, pins and shims. Front Brake Disc Set-Renew 4. Install pads and shims to calliper. 5. Install retaining pins and spring to calliper. Repair Operation Time (ROT) 6.
  • Page 189 Front Disc Brake (06.03) Brake Systems (06.00) Front Brake Hose Assembly-Renew Installation 1. Clean disc shield and mating face on vertical link. Repair Operation Time (ROT) 2. Install disc shield and torque tighten Torx screws (x4). Item Code 3. Install RH hub and bearing assembly (see Workshop Front Brake Hose Assembly-Renew 06.03.AE Manual procedure 04.01.AA Hub &...

  • Page 190: Rear Disc Brakes (06.04)

    Rear Disc Brakes (06.04) Brake system (06.00) Brake system (06.00) Rear Disc Brakes (06.04) Description The rear, four piston, brake caliper is bolted directly to the vertical link by two bolts. The caliper is a monobloc assembly. The steel brake discs are ventilated and grooved. They are secured to the hub by two retaining bolts. Specifications Torque Figures Description...

  • Page 191: Rear Disc Brakes (06.04)

    Rear Disc Brakes (06.04) Brake system (06.00) Maintenance Installation 1. Clean components (pads, pins, shims, spring) Rear Brake Disc Set-Renew 2. Install new calliper and secure bolts (x2) (torque). Repair Operation Time (ROT) 3. Apply anti-seize compound to pads, pins and shims. Item Code 4.
  • Page 192 Rear Disc Brakes (06.04) Brake system (06.00) Rear Brake Hose Assembly-Renew 3. Remove Torx screws (x4), disc shield to vertical link, remove shield. Repair Operation Time (ROT) Installation Item Code 1. Clean disc shield and mating face on vertical link. Rear Brake Hose Assembly-Renew 06.04.AE 2.
  • Page 193 Rear Disc Brakes (06.04) Brake system (06.00) 6-2-4 Workshop Manual October 2005...

  • Page 194: Hand Brake (06.05)

    Hand Brake (06.05) Brake Systems (06.00) Brake Systems (06.00) Hand Brake (06.05) Description The handbrake control lever is located on the outside of the drivers seat and brakes the rear road wheels through a cable system and two mechanical handbrake callipers. Handbrake pads are applied by the mechanical brake callipers (x2), one acting on each rear road wheel brake disc.

  • Page 195: Handbrake Pad Set-Renew

    Hand Brake (06.05) Brake Systems (06.00) Maintenance Handbrake Lever Assembly-Renew RH/LH Handbrake Calliper-Renew Repair Operation Time (ROT) Item Code Repair Operation Time (ROT) Handbrake Lever Assembly-Renew 06.05.CB Item Code Removal Handbrake Calliper-Renew 06.05.AB 1. Remove driver's seat (see Workshop Manual procedure Handbrake Calliper-Renew 06.05.BB 01.10.AB Seat Assembly - Front - LH - Remove for...

  • Page 196: Handbrake Cable Assembly-Adjust

    Hand Brake (06.05) Brake Systems (06.00) 10. Lower vehicle on ramp. 9. Remove screws (x4) from cable clips and unclip grommet from body clip (see Fig. 1). Handbrake Cable Assembly-Adjust Repair Operation Time (ROT) Item Code Handbrake Cable Assembly-Adjust 06.05.DC 1.
  • Page 197 Hand Brake (06.05) Brake Systems (06.00) 9. Adjust handbrake cable (see Workshop Manual procedure 06.05.DC Handbrake Cable Assembly - Renew). 10. Install road wheel/s. 11. Lower vehicle on ramp. 6-3-4 Workshop Manual October 2005...

  • Page 198: Brake Actuation System (06.06)

    Brake Actuation System (06.06) Brake System (06.00) Brake System (06.00) Brake Actuation System (06.06) Description Brake Fluid Reservoir Tandem Master Cylinder The brake fluid reservoir is mounted directly on the tandem master cylinder and secured with a pin. Two stub pipes, on the base of the reservoir, locate into the primary and secondary chambers of the tandem master cylinder.

  • Page 199: Maintenance

    Brake Actuation System (06.06) Brake System (06.00) Maintenance 12. Disconnect WDS from vehicle. RHD-Brake Master Cylinder Assembly- Manual Brake and Clutch Pedal-Bleed Renew Repair Operation Time (ROT) Repair Operation Time (ROT) Item Code Item Code Manual Brake and Clutch Pedal-Bleed 06.06.AD Brake Master Cylinder Assembly- RHD 06.06.EB...
  • Page 200 Brake Actuation System (06.06) Brake System (06.00) RH/LH Front Calliper Hose Assembly- 3. Install reservoir holding screw for access to master Renew cylinder retaining nut 4. Connect brake pipes to master cylinder. Repair Operation Time (ROT) 5. Connect clutch reservoir feed pipe. Item Code 6.
  • Page 201 Brake Actuation System (06.06) Brake System (06.00) RH/LH Rear Brake Calliper Tube 2. Remove road wheel(s). 3. Remove LH front wheel arch liner (see Workshop Assembly-Renew Manual procedure 01.02.FB Wheel Arch Liner - Front - Repair Operation Time (ROT) LH - Renew). Item Code 4.
  • Page 202 Brake Actuation System (06.06) Brake System (06.00) 6. Position bleed container, connect bleed hose to LHF 9. Tighten RHF/LHF bleed nipple, disconnect bleed hose, calliper, open bleed nipples (x1). remove bleed container and fit dust cap. 7. Depress brake pedal >60 mm and secure with support. 10.
  • Page 203 Brake Actuation System (06.06) Brake System (06.00) Installation 8. Clean off excess fluid. 9. Top-up brake fluid. 1. Install brake tube, connect unions, secure brake tube in 10. Install road wheel(s)). clips (x4), torque tighten unions. 11. Lower vehicle on ramp. 2.
  • Page 204 Brake Actuation System (06.06) Brake System (06.00) Installation 1. Install modulator to mounting bracket, install and torque tighten Torx bolts (x3). 2. Install modulator to body, install and torque tighten Torx bolts (x3). 3. Remove plugs. Install and torque tighten brake unions (x6) to modulator.
  • Page 205 Brake Actuation System (06.06) Brake System (06.00) 6-4-8 Workshop Manual October 2005...

  • Page 206: Power Brake System (06.09)

    Power Brake System (06.07) Brake System (06.00) Brake System (06.00) Power Brake System (06.07) Brake Booster The brake booster comprises a chamber divided by a diaphragm plate and is secured to the brake pedal housing. As the brake pedal is pressed, a poppet valve opens allowing atmospheric pressure into the drivers side of the diaphragm. Atmospheric pressure builds up on the drivers side of the diaphragm and pushes against the partial vacuum on the other side.

  • Page 207: Brake Fluid Reservoir-Renew

    Power Brake System (06.07) Brake System (06.00) Specifications 9. Disconnect multiplugs (x4). 10. Disconnect brake pipes from master cylinder (move Torque Figures aside). Description lb. / ft. 11. Remove booster assembly. Brake Booster Mount 21-24 15.5-18 12. Split components. Maintenance 13.
  • Page 208 Power Brake System (06.07) Brake System (06.00) 7. Install expansion tank aside (bolt x1, nut x1, hose clips 8. Disconnect clutch reservoir feed pipe. x2, multiplug x1). 9. Disconnect multiplugs (x4). 8. Install corner cross brace (torque) (only fully tighten 10.
  • Page 209 Power Brake System (06.07) Brake System (06.00) 9. Bleed Brakes (see Workshop Manual procedure 006.07.DD Brake Hydraulic System - Flush/Refill/ Bleed). 10. Top-up coolant. 6-5-4 Workshop Manual October 2005...

  • Page 210: Anti-Lock Braking System (Abs) (06.09)

    Anti-lock Braking System (ABS) (06.09) Brake system (06.00) Brake system (06.00) Anti-lock Braking System (ABS) (06.09) The anti-lock braking system (ABS) is a four-channel system having independent inputs from all four-wheel speed sensors. The ABS module, monitors signals from the sensors to calculate, brake slip and the acceleration / deceleration of individual wheels.

  • Page 211: System Overview

    Anti-lock Braking System (ABS) (06.09) Brake system (06.00) difference between the ideal and actual response within a • During the transient phase of torque reduction caused by tolerance band. This directly influences the forces on the mechanical and combustion delays, other alternative tires to generate a corrective yaw moment to reduce the side torque reduction methods are used to provide a quicker forces of the tires where appropriate...

  • Page 212: Engine Intervention

    Anti-lock Braking System (ABS) (06.09) Brake system (06.00) Engine Intervention Brake Intervention This function operates by increasing the pressure in the In the event of wheel-slip the ABS / DSC module calculates brake caliper of the slipping wheel, by closing the separation the torque, which should be applied by the engine to reduce valve and the inlet valve of the non-slipping wheel and the wheel-slip (this torque does not exceed driver demand).
  • Page 213 Anti-lock Braking System (ABS) (06.09) Brake system (06.00) 3. Remove ABS sensor multiplug (see Fig. 1). 3. Install sensor multiplug. 4. Install road wheel/s 5. Lower vehicle on ramp. Fig. 1 4. Remove ABS sensor and screw (x1) (see Fig. 2). Fig.

  • Page 214: Transmission (07.00)

    Transmission (07.00) Contents Transmission Cooling (07.02) .......7-1-2 Specifications............1-2 Maintenance ............1-2 Oil Cooler Matrix-Renew ........1-2 Manual Transmission Oil Outlet Hose-Renew ..1-3 Manual Transmission Oil Inlet Hose-Renew ... 1-3 Manual Transmission (07.03)........7-2-1 Description ............. 2-1 Cooling..............2-1 Specifications............2-2 Maintenance ............

  • Page 215: Transmission Cooling (07.02)

    Transmission Cooling (07.02) Transmission (07.00) Transmission (07.00) Transmission Cooling (07.02) 4. Loosen oil cooler pipe unions (x2) (see Fig. 1). Specifications Torque Figures Description lb. / ft. Cooler to subframe 8-10 6-7.5 Maintenance Oil Cooler Matrix-Renew Repair Operation Time (ROT) Item Code Oil Cooler Matrix-Renew...

  • Page 216: Manual Transmission Oil Outlet Hose-Renew

    Transmission Cooling (07.02) Transmission (07.00) Installation 6. Disconnect oil cooler pipes and remove oil cooler (see Fig. 2). 1. Clean hose connections and remove plugs. 2. Position hose, align brackets, install insulating washers (x2) and plain washer. 3. Install and tighten bolt and nuts (x2) to correct torque. 4.
  • Page 217 Transmission Cooling (07.02) Transmission (07.00) 7-1-4 Workshop Manual October 2005...

  • Page 218: Manual Transmission (07.03)

    Manual Transmission (07.03) Transmission (07.00) Transmission (07.00) Manual Transmission (07.03) Description The Graziano rear transaxle installed to this vehicle incorporates a six speed transmission plus reverse, with synchromesh on all gears. Gear selection is via an Integrated Shifter Bellcrack System (Cable Operated). Cooling The manual transaxle has an external cooling circuit which operates continuously by a fixed displacement pump driven...

  • Page 219: Specifications

    Manual Transmission (07.03) Transmission (07.00) Specifications Maintenance Transaxle Assembly-Remove for Access/ Type Refit Graziano AM803T transaxle with: • Integrated Shifter Bellcrack System (Cable Operated) Repair Operation Time (ROT) • Integrated Reverse Switch Item Code • Plate Type Limited Slip Differential Transaxle Assembly-Remove for 07.03.AA Synchronisers...
  • Page 220 Manual Transmission (07.03) Transmission (07.00) 10. Remove bolt securing earth lead to transaxle (see Fig. 2). 15. Loosen unions and disconnect oil cooler pipes (x2) from transaxle interconnecting pipes (see Fig. 5) Fig. 2 Fig. 5 11. Mark drive shaft to differential flanges for assembly purposes.
  • Page 221 Manual Transmission (07.03) Transmission (07.00) 20. Position hydraulic lifter to support transaxle (see Fig. 8). 26. Release reverse lamp switch multiplug from bracket and disconnect multiplug (see Fig. 11). Fig. 8 21. Remove and discard bolts (x8 - 4 each side) from mounting brackets to transaxle (see Fig.

  • Page 222: Transaxle Assembly-Oil Check/Top-Up

    Manual Transmission (07.03) Transmission (07.00) 29. With assistance, manoeuvre and remove transaxle from 25. Install road wheel(s). subframe (see Fig. 14). 26. Lower vehicle on ramp and remove securing straps. 27. Connect vehicle battery. 28. Test drive vehicle. 29. Raise vehicle on ramp and check transaxle oil level. 30.

  • Page 223: Transaxle Assembly-Renew

    Manual Transmission (07.03) Transmission (07.00) 8. Remove drain container. 8. Remove reverse light switch from transaxle (see Fig, 3). 9. Lower vehicle on ramp. Transaxle Assembly-Renew Repair Operation Time (ROT) Item Code Transaxle Assembly-Renew 07.03.CB Removal 1. Remove transaxle assembly (see Workshop Manual procedure 07.03.AA Transaxle Assembly - Manual - Remove for Access &...
  • Page 224 Manual Transmission (07.03) Transmission (07.00) 2. Install selector levers (x2) and install and torque tighten nuts (x2). 3. Install selector cable bracket and install and torque tighten bolts (x3). 4. Install and torque tighten reverse light switch. 5. Install oil cooler pipe assembly. 6.
  • Page 225 Manual Transmission (07.03) Transmission (07.00) 7-2-8 Workshop Manual October 2005...

  • Page 226: Manual Control System (07.06)

    Exterior Trim (01.08) Transmission (07.00) Transmission (07.00) Manual Control System (07.06) 10. Remove centre pipe and rear exhaust pipes as an assembly. Maintenance 11. Remove bolts (x4), centre heatshield to body, remove heatshield. Gearshift Assembly Mechanism-Renew 12. Remove bolts (x8), shear plate to body, remove shear plate.
  • Page 227 Exterior Trim (01.08) Transmission (07.00) 14. Install rear exhaust muffler (see Workshop Manual procedure 09.00.KA Silencer and Bypass Valve Assembly - Remove for Access & Refit). 15. Install road wheel(s). 16. Lower vehicle on ramp, remove securing straps. 17. Position selector cable in bracket, install horseshoe clip. 18.

  • Page 228: Clutch (08.00)

    Clutch (08.00) Contents Clutch Assembly (08.01)........8-1-2 Description ............. 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 ...... 1-3 Clutch Hydraulic System-Bleed ......1-4 Clutch Assembly (08.01)........8-1-2 Description ............... 1-2 Specifications ............

  • Page 229: Clutch Assembly (08.01)

    Clutch Assembly (08.01) Clutch (08.00) Clutch Assembly (08.01) 5. Install special tool SKAM14546 OT to restrain flywheel and install and tighten bolts (x2) (see Fig. 1). 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.

  • Page 230: Slave Clutch Cylinder-Renew

    Clutch Assembly (08.01) Installation 6. Remove bolts (x2) that secure slave cylinder to torque tube (see Fig. 2). 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.

  • Page 231: Clutch Hydraulic System-Bleed

    Clutch Assembly (08.01) 6. Bleed clutch (see Workshop Manual procedure XREF: 574 Clutch Hydraulic System - Bleed). 7. Install deflector - front floor heatshield (see Workshop Manual procedure 09.04.AA Heatshield - Front Floor - Renew). 8. Lower vehicle on ramp. Clutch Hydraulic System-Bleed Repair Operation Time (ROT) Item...

  • Page 232: Exhaust (09.00)

    Exhaust (09.00) Contents Exhaust Overview ..........9-1-2 Silencer Assembly (09.01) ........9-1-3 Variable Flow Silencer Assembly ......1-3 Pipes and Supports (09.03) ........9-2-1 Specifications............2-1 Maintenance ............2-1 Exhaust System ............2-1 Removal.............. 2-1 Installation ............2-2 October 2005 Workshop Manual 9-1-1...

  • Page 233: Exhaust Overview

    Exhaust Overview Exhaust System (09.00) Exhaust System (09.00) Exhaust Overview The exhaust system consists of two four-branch manifolds, two catalytic converters, 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. •...

  • Page 234: Silencer Assembly (09.01)

    Silencer Assembly (09.01) Exhaust (09.00) Exhaust (09.00) Silencer Assembly (09.01) Variable Flow Silencer Assembly The rear silencer assembly has a variable flow path controlled by two bypass valves. The system is intended to enhance top end performance in motor sport applications and will not operate in most normal driving conditions.
  • Page 235 Silencer Assembly (09.01) Exhaust (09.00) 3. Remove Allen bolts (x4), bumper diffuser to mounting 5. Remove rubber mounting from hanger bracket. brackets. Remove diffuser, collect securing brackets. Installation 4. Disconnect both by-pass valve vacuum lines. 1. To aid assembly, apply liquid soap to rubber mounting. 5.

  • Page 236: Pipes And Supports (09.03)

    Pipes and Supports (09.03) Exhaust System (09.00) Exhaust System (09.00) Pipes and Supports (09.03) 8. Remove string (x2), connect multiplugs (x2), HEGO sensors. Specifications 9. Install rear exhaust silencer (see Workshop Manual procedure 09.00.KA Silencer and Bypass Valve Assembly - Remove for Access & Refit). Torque Figures 10.
  • Page 237 Pipes and Supports (09.03) Exhaust System (09.00) Removal 3. Install nuts (x8) securing manifold to cylinder head (torque). 1. Remove wheel arch liner (see Workshop Manual 4. Install LH front wheel arch liner (see Workshop Manual procedure 01.02.GB Wheel Arch Liner - Front - RH - procedure 01.02.FB Wheel Arch Liner - Front - LH - Renew).

  • Page 238: Exhaust System

    Pipes and Supports (09.03) Exhaust System (09.00) LH Exhaust Manifold Gasket-Renew 5. Install rear intermediate pipe to centre pipe. 6. Align rear intermediate pipe to silencer. Repair Operation Time (ROT) 7. Install rear muffler assembly (see Workshop Manual Item Code procedure 09.00.KA Silencer &...
  • Page 239 Pipes and Supports (09.03) Exhaust System (09.00) 23. Remove bolts (x11), heatshields to centre, LH and RH rear pipes. Remove heatshields. Installation 1. Clean heatshields. 2. Position heatshields to centre, LH and RH rear pipes. Install and tighten bolts. 3. Install new flange gaskets to exhaust manifolds. 4.
  • Page 240 Exhaust Protection (09.04) Exhaust (09.00) Exhaust (09.00) Exhaust Protection (09.04) 2. Remove bolts/washers (x4) securing tunnel heatshield to body, remove heatshield. Maintenance Installation 1. Install tunnel heatshield, install washers/nuts (x), torque Front Floor Heatshield-Renew tighten nuts. Repair Operation Time (ROT) 2.

  • Page 241: Fuel (10.00)

    Fuel (10.00) Contents Fuel Tank and Lines (10.01) ........8-1-2 Description ............. 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 ........... 1-6 Evaporative Loss System......... 1-6 System Operation ..........

  • Page 242: Fuel Tank And Lines (10.01)

    Fuel Tank and Lines (10.01) Fuel (10.00) 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 sensor and a temperature sensor are fitted on the primary fuel rail.

  • Page 243: Fuel Tank

    Fuel Tank and Lines (10.01) Fuel (10.00) 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 During normal running, pressurised 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.

  • Page 244: Jet Pumps

    Fuel Tank and Lines (10.01) Fuel (10.00) Jet Pumps Filler Neck and Check Valve Fuel feed from the fuel pumps is split three ways: Incoming fuel passes through a check valve at the base of the filler neck. This valve is normally held closed by light spring 1.

  • Page 245: Valves And Sensors

    Fuel Tank and Lines (10.01) Fuel (10.00) Valves and Sensors Fuel System Schematic Fuel Limit Vent Valve (FLVV) This valve contains a float which rises to cut off the path for displaced air when the fuel level rises towards maximum during fuel filling.

  • Page 246: Evaporative Loss System

    Fuel Tank and Lines (10.01) Fuel (10.00) 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.

  • Page 247: Safety Precautions

    Fuel Tank and Lines (10.01) Fuel (10.00) 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.

  • Page 248: Maintenance

    Fuel Tank and Lines (10.01) Fuel (10.00) Maintenance 3. Release and remove luggage compartment rear floor carpet. Fuel System 4. Remove luggage compartment front floor carpet retainers (x6). The fuel system must only be serviced by staff trained in fuel handling.

  • Page 249: Fuel Tank And Canister Assembly-Remove For Access/Refit

    Fuel Tank and Lines (10.01) Fuel (10.00) Fuel Tank and Canister Assembly- Carbon Canister Assembly-Renew Remove for Access/Refit Repair Operation Time (ROT) Repair Operation Time (ROT) Item Code Item Code Carbon Canister Assembly-Renew 10.01.GB Fuel Tank and Canister Assembly- 10.01.GA Removal Remove for Access/Refit 1.

  • Page 250: Fuel Vapour Pipe Assembly-Renew

    Fuel Tank and Lines (10.01) Fuel (10.00) 5. Install luggage compartment rear floor carpet 5. Connect vehicle battery. 6. Connect battery earth lead. Manifold Supply Fuel Pipe Assembly- Renew Fuel Vapour Pipe Assembly-Renew Repair Operation Time (ROT) Repair Operation Time (ROT) Item Code Item...

  • Page 251: Fuel Tank Filler Pipe And Hose Assembly-Renew

    Fuel Tank and Lines (10.01) Fuel (10.00) Fuel Tank Filler Pipe and Hose Assembly-Renew Repair Operation Time (ROT) Item Code Fuel Tank Filler Pipe and Hose 10.01.LC Assembly-Renew Removal 1. Remove LH rear wheel arch liner (see Workshop Manual procedure 01.02.JB Wheel Arch Liner - Rear - LH - Renew).

  • Page 252: Steering (11.00)

    Steering (11.00) Contents Steering Gear (11.01) ..........11-1-2 Diagnostics - Symptom Chart......... 1-2 Specifications............1-4 Maintenance ............1-4 LH Track Rod End-Renew........1-4 RH Track Rod End-Renew ........1-4 Power Steering (11.02) ........11-2-1 Description ............. 2-1 Specifications............2-1 Maintenance ............2-2 System Bleeding.............

  • Page 253: Steering Gear (11.01)

    Steering Gear (11.01) Steering (11.00) Steering (11.00) Steering Gear (11.01) Diagnostics - Symptom Chart Symptom Possible Cause Action Vehicle wanders Incorrect tyre size or pressure. Check for correct tyre size. from side to side on Adjust tyre pressures. the road when Vehicle unevenly loaded or overloaded.
  • Page 254 Steering Gear (11.01) Steering (11.00) Symptom Possible Cause Action Vehicle tends to pull Incorrect tyre pressure. Adjust tyre pressure. to one side when Incorrect tyre size. New tyre as required. driven on a level Different tyre or tread type. surface. Vehicle is unevenly or excessively loaded.

  • Page 255: Specifications

    Steering Gear (11.01) Steering (11.00) Symptom Possible Cause Action Excessive steering Dirty fluid filter. Clean/replace reservoir. efforts required to Low power steering pump fluid. Fill as required. Check for system leaks. turn corners and Damaged accessory drive belt tensioner. New accessory drive belt tensioner. during parking Hose or oil cooler external leak.

  • Page 256: Power Steering (11.02)

    Power Steering (11.02) Steering (11.00) Steering (11.00) Power Steering (11.02) Description Specifications The power steering system comprises of a non-speed sensitive rack and pinion steering gear together with an engine driven vane pump, operating at a constant flow rate. Item Data The level of assistance is controlled via a rotary hydraulic Pump Pressure (max)

  • Page 257: Maintenance

    Power Steering (11.02) Steering (11.00) Maintenance 4. Install reservoir cap. Power Steering Pump to Rack Hose Power Assisted Steering System-Bleed Assembly-Renew Repair Operation Time (ROT) Repair Operation Time (ROT) Item Code Item Code Power Assisted Steering System-Bleed 11.01.AA Power Steering Pump to Rack Hose 11.02.EA Removal Assembly-Renew...

  • Page 258: Power Steering Cooler To Reservoir Hose And Clip Assembly-Renew

    Power Steering (11.02) Steering (11.00) Power Steering Cooler to Reservoir Hose and Clip Assembly-Renew Repair Operation Time (ROT) Item Code Power Steering Cooler to Reservoir 11.02.ED Hose and Clip Assembly-Renew Removal 1. Remove radiator grille (see Workshop Manual procedure 01.08.AA Grille - Radiator - Renew). 2.
  • Page 259 Power Steering (11.02) Steering (11.00) 11-2-4 Workshop Manual October 2005...

  • Page 260: Steering Column (11.04)

    Steering Column (11.04) Steering (11.00) Steering (11.00) Steering Column (11.04) 8. Remove screws (x7) and remove steering column shrouds (see Fig. 1). Description The steering column has reach and tilt functions. These allow the driver to manually set the steering column position by using the reach / tilt lever, located on the underside of the steering column, regardless of the ignition switch position.
  • Page 261 Steering Column (11.04) Steering (11.00) 22. Remove Torx screws (x3) that secure steering sensor mounting bracket to column and remove bracket. Installation 1. Position steering sensor mounting bracket, install and tighten Torx screws (x3). 2. Install steering sensor, install and tighten Torx screws (x3).

  • Page 262: Steering Column Switches (11.05)

    Steering Column Switches (11.05) Steering (11.00) Steering (11.00) Steering Column Switches (11.05) Maintenance 6. Install upper steering column shrouds and tighten screws (x7). Ignition Switch-Renew 7. Install steering wheel (see Workshop Manual procedure 11.06.AB Steering Wheel Renew). Repair Operation Time (ROT) 8.

  • Page 263: Cruise Control Switch-Renew

    Steering Column Switches (11.05) Steering (11.00) Cruise Control Switch-Renew Repair Operation Time (ROT) Item Code Cruise Control Switch-Renew 11.06.BL Removal 1. Remove Airbag module (see Workshop Manual procedure 11.06.BC Module - Drivers Airbag - Renew). 2. Remove cruise control switch. Installation 1.

  • Page 264: Steering Wheel (11.06)

    Steering Wheel (11.06) Steering (11.00) Steering (11.00) Steering Wheel (11.06) Specifications Maintenance Steering Wheel-Renew Repair Operation Time (ROT) Item Code Steering Wheel-Renew 11.06.AB Removal 1. Disconnect vehicle battery. 2. Remove driver's airbag module (see Workshop Manual Procedure 11.06.BC Module - Drivers Airbag - Renew). 3.
  • Page 265 Climate Control (12.00) Contents Body Ventilation (12.01)........12-1-2 Air Intake & Distribution System......1-2 Air Intake Actuator..........1-3 Air Mix Actuator ............ 1-3 Airflow Mode Actuator........... 1-4 Maintenance ............1-5 RH/LH Centre Facia Ventilator Outlet-Renew ..1-5 LH Facia Ventilator Outlet-Renew......1-5 RH Facia Ventilator Outlet-Renew ......

  • Page 266: Climate Control (12.00)

    Body Ventilation system (12.01) Climate Control (12.00) Climate Control (12.00) Body Ventilation (12.01) Air Intake & Distribution System Air flows from the cabin into the boot via air vent grilles and through apertures in the rear parcel shelf. The air is Outside air enters the plenum via inlets at the base of the exhausted from the vehicle through extraction vent windscreen.

  • Page 267: Air Intake Actuator

    Body Ventilation system (12.01) Climate Control (12.00) Air Intake Actuator Air Mix Actuator Inspection Inspection 1. Connect the battery positive voltage to Intake Actuator 1. Connect the battery positive voltage to Air Mix Actuator terminal 1 (or 3), and ground to terminal 3 (or 1). terminal 6 (or 7), and ground to terminal 7 (or 6).

  • Page 268: Airflow Mode Actuator

    Body Ventilation system (12.01) Climate Control (12.00) Airflow Mode Actuator VENT Inspection 90° C0413 1. Connect the battery positive voltage to the Airflow Mode Actuator terminal 6 (or 7), and ground to terminal 32° 7 (or 6). Verify that the Airflow Mode Actuator operates DEFROSTER as shown.

  • Page 269: Rh/Lh Centre Facia Ventilator Outlet-Renew

    Body Ventilation system (12.01) Climate Control (12.00) Maintenance Installation 1. Install vent outlet, push into aperture and secure with RH/LH Centre Facia Ventilator Outlet- screws (x3) Renew 2. Install passenger's upper outer panel assembly Repair Operation Time (ROT) 3. Install airbag panel and door assembly (see Workshop Manual procedure 01.12.AV Bezel Assembly - Item Code...
  • Page 270 Body Ventilation system (12.01) Climate Control (12.00) 12-1-6 Workshop Manual October 2005...

  • Page 271: Heater System (12.02)

    Heater System (12.02) Climate Control (12.00) Heater System (12.02) Maintenance RHD/LHD Heater Unit (Including ECU)- Renew Repair Operation Time (ROT) Item Code Heater Unit (Including ECU)-Renew RHD 12.03.AF Heater Unit (Including ECU)-Renew LHD 12.03.AD Removal 1. Remove IP unit from vehicle (see Workshop Manual procedure 01.12.AB Facia Assembly LHD Remove for Access &...
  • Page 272 Heater System (12.02) 12-2-2 Workshop Manual October 2005...

  • Page 273: Air Conditioning (A/C) System (12.03)

    Air Conditioning (A/C) System (12.03) Climate Control (12.00) Climate Control (12.00) Air Conditioning (A/C) System (12.03) Item 1. Condenser 6. Low-side charge. 2. Trinary switch 7. Blower Unit. 3. Compressor assembly 8. Switch, A/C Cut-Off. 4. High-side charge port 9. Expansion valve. 5.

  • Page 274: Major Components

    Air Conditioning (A/C) System (12.03) Climate Control (12.00) Major Components A/C Unit Compressor • Engine mounted, driven by the accessory drive belt • Variable displacement type • High-pressure relief valve, to avoid system over-pressure • ECU controlled clutch energised via a relay Receiver drier •...

  • Page 275: Refrigerant System

    Warning Avoid breathing A/C refrigerant or lubricant vapor. Exposure may irritate eyes, nose and throat. Also, due to environmental concerns, Aston Martin recommend the use of a recovery / recycling / recharging unit when draining R-134a from the A/C system.

  • Page 276: Handling Insufficient Refrigerant Level

    Air Conditioning (A/C) System (12.03) Climate Control (12.00) Handling Insufficient Refrigerant Level Refrigeration Cycle Caution If an insufficient refrigerant level is detected while troubleshooting, do not charge (add) the refrigerant. Because an accurate amount of refrigerant cannot be determined from the pressure indicated on the recovery / recycling / recharging unit, never charge the refrigerant.

  • Page 277: Specifications

    Air Conditioning (A/C) System (12.03) Climate Control (12.00) wheel' and the excess pressure will be dissipated through the expansion valve. When the pressure drops below 27.6 bar, the safety valve will close again and the compressor will be operative. The terms ‘high’ and ‘low’ pressure (or side) refer to the pressure differential between the compressor and expansion valve ports.

  • Page 278: Diagnostics

    Air Conditioning (A/C) System (12.03) Climate Control (12.00) Diagnostics Electrical Connectors A/C Module (C0791) Pin Specification Air flow mode actuator (output) Temperature actuator (output) A/C Module (C0792) Blank Pin Specification Blank V Battery (from CCM) Blank V Ignition (from comfort relay) A/C On (A/C pressure sensor) Recirculation acutuator Blank...

  • Page 279: Dtc Inspection

    Air Conditioning (A/C) System (12.03) Climate Control (12.00) DTC Inspection Using WDS 1. Connect the WDS to the body diagnostic socket (Refer to ’Appendix & Glossary’, page 20-1-2). 2. Select ‘Air-Con’ from the menu. 3. Read the fault codes from the WDS screen. Single Fault Codes Code Description Possible Cause...

  • Page 280: Multiple Fault Codes

    Air Conditioning (A/C) System (12.03) Climate Control (12.00) Code Description Possible Cause Ambient temperature sensor system 1. Ambient temperature sensor fault inspection. 2. Open or short circuit in the wiring harness between the A/C module and the ambient temperature sensor Code Description Possible Cause ECT sensor system inspection.

  • Page 281: Maintenance

    Air Conditioning (A/C) System (12.03) Climate Control (12.00) Maintenance 1. Connect an R-134a Recovery / Recycling / Recharging Assessment of the A/C system operating efficiency and fault unit to the vehicle A/C system. classification may be achieved by using the facilities on a 2.

  • Page 282: A/C System Testing

    Air Conditioning (A/C) System (12.03) Climate Control (12.00) A/C System Testing 7. Close all the doors and windows. 8. Wait until the A/C output temperature stabilizes. It is recommended that a free standing air mover is placed Stabilized condition. in front of the condenser / cooling system. The A/C compressor repeatedly turns on and off at regular Pressure Check intervals.

  • Page 283: Leaks

    Air Conditioning (A/C) System (12.03) Climate Control (12.00) Leaks Faults associated with low refrigerant charge weight and low pressure may be caused by leakage. Leaks traced to mechanical connections may be caused by torque relaxation or joint face contamination. Evidence of oil around such areas is an indicator of leakage.

  • Page 284: Maintenance

    Air Conditioning (A/C) System (12.03) Climate Control (12.00) Maintenance 2. Remove bolts (x2) that secure pipes to receiver drier and remove and discard 'O' rings (x2) from pipe connections. Condenser-Renew Plug pipe connections (see Fig. 1). Repair Operation Time (ROT) Item Code Condenser-Renew...

  • Page 285: Lower Evaporator Outlet Tube Assembly-Renew

    Air Conditioning (A/C) System (12.03) Climate Control (12.00) Lower Evaporator Outlet Tube Assembly- 6. Disconnect upper pipe from lower pipe using special Renew tool (412-038 black) and remove upper pipe. 7. Mark relative position of P-clip then remove clip from Repair Operation Time (ROT) pipe.
  • Page 286 Air Conditioning (A/C) System (12.03) Climate Control (12.00) Condenser to Receiver Drier Tube 2. Connect multiplug to blower motor. Assembly-Renew 3. Battery isolation switch ‘ON’. 4. Power passenger seat to original position. Repair Operation Time (ROT) Pollen Filter-Renew Item Code Condenser to Receiver Drier Tube 12.03.GB Repair Operation Time (ROT)
  • Page 287 Air Conditioning (A/C) System (12.03) Climate Control (12.00) Troubleshooting The areas for inspection (steps) are given according to various circuit malfunctions. Use the following chart to verify the symptoms of the trouble in order to diagnose the appropriate area. Symptom(1) Description Possible Cause Insufficient air (or no air) blown...
  • Page 288 Air Conditioning (A/C) System (12.03) Climate Control (12.00) Symptom (7) Description Possible Cause Air from vents not cold enough. Magnetic clutch operates but A/ • Drive belt fault C system malfunctions. • Fault in blower unit or condenser • Fault in Receiver / Drier or expansion valve (valve closes too much) •...

  • Page 289: Climate Subsystem (12.04)

    Climate Subsystem (12.04) Climate Control (12.00) Climate Control (12.00) Climate Subsystem (12.04) A/C Re-circulation Switch-Renew Maintenance Repair Operation Time (ROT) Item Code Solar Load Sensor-Renew A/C Re-circulation Switch-Renew 15.01.CM Repair Operation Time (ROT) Removal Item Code 1. Remove centre stack assembly (see Workshop Manual Solar Load Sensor-Renew 12.04.AA procedure 15.01.CB Centre Stack Assembly - Remove...

  • Page 290: Information, Gauge And Warning (13.00)

    Information, Gauge and Warning (13.00) Contents Driver Information Module (DIM) (13.01) ..13-1-2 Description ............. 1-2 Information and Warning Lamps ......1-3 DIM Display layout ..........1-4 Maintenance ............1-5 Driver Information Module-Renew ......1-5 Horn Subsystem (13.06) ........13-2-1 Maintenance ............2-1 Horn-Renew ............

  • Page 291: Instrument Cluster (13.01)

    Instrument Cluster (13.01) Information, Gauge and Warning (13.00) Information, Gauge and Warning (13.00) Instrument Cluster (13.01) Description The Driver Information module contains the necessary electronic control units and memories to control, process and present all necessary vehicle information to the driver. 1.

  • Page 292: Information And Warning Lamps

    Instrument Cluster (13.01) Information, Gauge and Warning (13.00) Information and Warning Lamps Name / Function Description Symbol Input Signal Power On Check General Warning Controlled internally by the DIM. It is used in conjunction with Internal – Amber/Red several text messages to indicate information to the driver. SRS (Airbag) Controlled externally by the SRS module and indicates a fault Yes (5 Seconds)

  • Page 293: Dim Display Layout

    Instrument Cluster (13.01) Information, Gauge and Warning (13.00) DIM Display layout Message Centre Right The Message Centre Right is used to display the trip function The DIM contains two message centres, which are used to information and warning/information messages. inform the driver about the vehicles status. Message Centres The left Message Centre is used to display the odometer (C), the Cruise control status (C) and the T1 or T2 trip distance...

  • Page 294: Maintenance

    Instrument Cluster (13.01) Information, Gauge and Warning (13.00) Maintenance Driver Information Module-Renew Repair Operation Time (ROT) Item Code Driver Information Module-Renew 13.01.AA Removal 1. Remove instrument cluster bezel panel (see Workshop Manual procedure 01.12.AT Panel - Bezel - Cluster - Renew).
  • Page 295 Instrument Cluster (13.01) Information, Gauge and Warning (13.00) 13-1-6 Workshop Manual October 2005...

  • Page 296: Horn Subsystem (13.06)

    Horn Subsystem (13.06) Information, Gauge and Warning (13.00) Information, Gauge and Warning (13.00) Horn Subsystem (13.06) Maintenance Horn-Renew Repair Operation Time (ROT) Item Code Horn-Renew 13.06.A Removal 1. Remove slam panel (screws x12). 2. Remove horn and bracket assembly (bolts x2) and disconnect multiplug.
  • Page 297 Horn Subsystem (13.06) Information, Gauge and Warning (13.00) 13-2-2 Workshop Manual October 2005...

  • Page 298: Parking/Reversing Aids (13.13)

    Parking/Reversing Aids (13.13) Information, Gauge and Warning (13.00) Information, Gauge and Warning (13.00) Parking/Reversing Aids (13.13) Installation 1. Install speaker and fit pop-rivets (x2). Maintenance 2. Connect multiplug. Rear Centre Parking Aid Sensor-Renew Repair Operation Time (ROT) Item Code Rear Centre Parking Aid Sensor-Renew 13.13.A Removal 1.
  • Page 299 Power Supply (14.00) Contents Battery System (14.01).........14-1-2 Description ............. 1-2 Battery Connect Switch.......... 1-2 Battery Disconnection and Alarm Activation... 1-2 Charging Circuit ............. 1-3 +12 Volt Distribution..........1-3 Specifications............1-4 Maintenance ............1-4 Vehicle Battery-Renew........... 1-4 Switch Battery Disconnect-Renew......1-4 Switch Battery Off-Renew ........

  • Page 300: Power Supply (14.00)

    Battery System (14.01) Power Supply (14.00) Power Supply (14.00) Battery System (14.01) Description The 12 volt negative earth (‘-’ ve) battery is located under the RH side rear seat and is grounded to the vehicle body. The battery positive (‘+’ ve) terminal is connected to a battery connect switch. The connect switch may be accessed by raising the rear seat cushion.

  • Page 301: Charging Circuit

    Battery System (14.01) Power Supply (14.00) Charging Circuit Electrical power generated at the alternator flows via two ‘T Piece’ connectors to the engine bay ‘Dirty Feed’ stud. It then flows via the Battery Disconnect Switch (BDS) to the battery positive terminal. Both the alternator and the battery are earthed via the vehicle body to complete the charging circuit.

  • Page 302: Specifications

    Battery System (14.01) Power Supply (14.00) Specifications 4. Remove panel assembly - quarter trim middle - RH (see Workshop Manual procedure 01.05.CT Panel Assembly - Quarter Trim Middle Section - RH - Renew). Torque Figures 5. Release rear carpet studs (x2), move carpet aside. Description lb.

  • Page 303: Battery Conditioner-Renew

    Battery System (14.01) Power Supply (14.00) 10. Position power support bracket, install bolt, torque 2. Remove nuts (x2), securing jump start terminal to tighten bolt and nuts (x2). mounting bracket. 11. Install carpet - RH side luggage compartment. (see 3. Remove nut securing battery cable to jump start Workshop Manual procedure 01.05.FB Carpet terminal.

  • Page 304: Bulkhead Stud To Starter Cable Assembly-Renew

    Battery System (14.01) Power Supply (14.00) 7. Remove nuts (x2), battery compartment cover to body. 3. Release rubber cover, remove nut securing cable to Remove cover. bulkhead stud, Remove cable. 8. Remove nut and washer securing battery cable to 4. Remove rubber cover from cable. battery disconnect switch.

  • Page 305: Bds To Bulkhead Dirty Feed Harness-Renew

    Battery System (14.01) Power Supply (14.00) BDS to Bulkhead Dirty Feed Harness- 2. Remove rear undertray (see Workshop Manual procedure 01.02.PB Undertray - Rear - Renew). Renew 3. Remove bolt securing engine earth strap to RH transaxle mounting bracket. Repair Operation Time (ROT) 4.
  • Page 306 Battery System (14.01) Power Supply (14.00) 14-1-8 Workshop Manual October 2005...

  • Page 307: Alternator And Regulator System (14.02)

    Alternator and Regulator System (14.02) Power Supply (14.00) Power Supply (14.00) Alternator and Regulator System (14.02) Description 10. Disconnect top hose from engine (clip x1) tie aside (catch coolant). The alternator installed to this vehicle is a Denso, SC1, 120 11.
  • Page 308 Alternator and Regulator System (14.02) Power Supply (14.00) 21. Release tensioner and slip belt on idler. 22. Install throttle body duct. 23. Connect breather pipe quickfits (x2) to air cleaner duct. 24. Battery isolation switch ‘ON’. 25. Top up coolant. 14-2-2 Workshop Manual October 2005...

  • Page 309: Vehicle Entertainment (15.00)

    Vehicle Entertainment (15.00) Contents Audio System ............15-1-1 Maintenance ............1-1 Power Amplifier-Renew ......... 1-1 Subwoofer Premium Amplifier-Renew ....1-1 Telephone Switchpack-Renew ....... 1-2 Infotainment Control Module-Renew..... 1-2 Display Screen-Renew ........... 1-3 Clock-Renew ............1-3 Satellite Navigation Switchpack-Renew ....1-3 CD Player-Renew ..........1-3 Tuner AM/FM-Renew ..........

  • Page 310: Audio System

    Audio System 9. Remove amplifier and bracket assembly. 10. Disconnect multiplugs (x3) from amplifier to audio Maintenance harness. 11. Remove nuts and bolts (x4) that secure power amplifier Power Amplifier-Renew to mounting plate and remove amplifier (see Fig. 3). Repair Operation Time (ROT) Item Code Power Amplifier-Renew...

  • Page 311: Telephone Switchpack-Renew

    2. Remove RH luggage compartment carpet (see 11. Remove bolts (x4) that secure subwoofer amplifier to Workshop Manual procedure 01.05.FB Carpet mounting plate and remove amplifier (see Fig. 3). Assembly - Luggage Compartment - Side - RH - Renew). 3. Remove bolt (x1) and nuts (x2) from power socket bracket to body (see Fig.

  • Page 312: Infotainment Control Module-Renew

    Infotainment Control Module-Renew 2. Install Infotainment Control Module (see Workshop Manual procedure 15.01.CF Infotainment Control Repair Operation Time (ROT) Module - Renew). Item Code Satellite Navigation Switchpack-Renew Infotainment Control Module-Renew 15.01.CF Repair Operation Time (ROT) Removal Item Code 1. Remove centre stack assembly (see Workshop Manual Satellite Navigation Switchpack-Renew 15.01.CJ procedure 15.01.CF Centre Stack Assembly - Remove...

  • Page 313: Gps Tuner-Renew

    2. Remove bolts (x4) from tuner base plate to wheel arch 2. Remove bolts (x4) from tuner base plate to wheel arch (see Fig. 1). (see Fig. 1). Fig. 1 Fig. 1 3. Remove bolts (x2) from GPS tuner to bracket (see Fig. 3.
  • Page 314 2. Depress clips and remove rear fog switch from centre stack. Installation 1. Install rear fog light switch and secure with clips. 2. Install centre stack assembly (see Workshop Manual procedure 15.01.CF Centre Stack Assembly - Remove for Access and Refit). Hazard Warning Switch-Renew Repair Operation Time (ROT) Item...

  • Page 315: Antenna (15.02)

    Antenna (15.02) Vehicle Entertainment (15.00) Vehicle Entertainment (15.00) Antenna (15.02) Maintenance GPS Antenna-Renew Repair Operation Time (ROT) Item Code GPS Antenna-Renew 19.07.DA Removal 1. Remove tailgate trim panel (see Workshop Manual procedure 01.05.EF Trim - Tailgate Lid Assembly - Renew). 2.
  • Page 316 Antenna (15.02) Vehicle Entertainment (15.00) 15-2-2 Workshop Manual October 2005...

  • Page 317: Speakers (15.03)

    Speakers (15.03) Vehicle Entertainment (15.00) Vehicle Entertainment (15.00) Speakers (15.03) 2. Remove bolts (x2) and screw (x1) securing upper quarter trim to body. Maintenance 3. Feed seatbelt through trim panel aperture and remove panel. RH/LH Front Door Speaker-Renew 4. Disconnect speaker multiplug. 5.

  • Page 318: Vacuum Distribution (16.00)

    Vacuum Distribution (16.00) Contents Body Vacuum System (16.01) ......16-1-2 Description .............1-2 Maintenance ............1-3 Vacuum Assembly Pump-Renew ......1-3 October 2005 Workshop Manual 16-1-1...

  • Page 319: Body Vacuum System (16.01)

    Body Vacuum System (16.01) Vacuum Distribution (16.00) Vacuum Distribution (16.00) Body Vacuum System (16.01) Description The exhaust system consists of four twin-branch manifold assemblies which direct exhaust gases through two under-floor catalysts (before feeding) via under-floor pipework to a two-stage rear silencer. The two-stage rear silencer directionally varies the flow of exhaust gas to give acceptable exhaust noise levels at low engine speeds and reduce exhaust back pressure for engine protection at high engine speeds.
  • Page 320 Body Vacuum System (16.01) Vacuum Distribution (16.00) Maintenance Vacuum Assembly Pump-Renew Repair Operation Time (ROT) Item Code Vacuum Assembly Pump-Renew 16.00.AD Removal 1. Remove rear bumper (see Workshop Manual procedure 01.19.BA Cover Assembly - Rear Bumper - Renew). 2. Disconnect vacuum pump multiplug. 3.
  • Page 321 Lighting (17.00) Contents Lighting (17.00) ............1-2 Front Lights (17.01) ..........17-1-2 Specifications............1-2 Maintenance ............1-2 RH/LH Headlamp Assembly-Renew ....... 1-2 Headlamp Alignment-Adjust ........1-3 Dip Beam Bulb-Renew .......... 1-3 Main Beam Bulb-Renew ........1-3 Side Repeater Lamp Assembly-Renew....1-3 Interior Lighting (17.02) ........17-2-1 Specifications............

  • Page 322: Lighting (17.00)

    Front Lights (17.01) Lighting (17.00) Lighting (17.00) Front Lights (17.01) 6. Disconnect headlamp washer supply hose (see Fig. 2). Specifications Bulbs Type Type Rating (European) (Federal) Headlight dipped beam-HID Headlight dipped H11LL H11LL beam-Halogen Headlight main beam 65W Side Repeater WY5W WY5W Side marker (front and...

  • Page 323: Dip Beam Bulb-Renew

    Front Lights (17.01) Lighting (17.00) 2. Connect multiplug and washer hose. Fig. 1 3. Install 3 Bolts from headlamp to bracket. 3. Disconnect multiplug and remove spring clip and bulb 4. Install intake air filter box (see Workshop Manual unit (see Fig. 2). procedure 03.12.AB/03.12.BB Air Filter Box LH/RH Renew).
  • Page 324 Front Lights (17.01) Lighting (17.00) 4. Turn the assembly clockwise (looking at the lens) and remove. Installation 1. Install assembly into front wing and turn counter- clockwise until the stop. 2. Install bulb and holder assembly. 3. Connect side repeater multiplug. 4.

  • Page 325: Interior Lighting (17.02)

    Interior Lighting (17.02) Lighting (17.00) Lighting (17.00) Interior Lighting (17.02) Specifications Bulbs Rating Type Reading lamp Boot lamp C10W October 2005 Workshop Manual 17-2-1...
  • Page 326 Interior Lighting (17.02) Lighting (17.00) 17-2-2 Workshop Manual October 2005...

  • Page 327: Rear Lights (17.03)

    Rear Lights (17.03) Lighting (17.00) Lighting (17.00) Rear Lights (17.03) 5. Remove nuts (x3), star washers (x3), plain washers (x3) and rubber seals (x3) (see Fig. 2). The rear light cluster is a sealed unit. If any light which fails to illuminate is traced back to the rear light cluster, replace the whole unit.

  • Page 328: Rh/Lh Reflector-Renew

    Rear Lights (17.03) Lighting (17.00) 3. Remove securing nuts (x2) and put unit to one side. Installation 1. Install light unit and secure with nuts (x2). 2. Connect multiplug. 3. Install tailgate trim panel (see Workshop Manual procedure 01.05.EF Trim - Tailgate Lid Assembly - Renew).

  • Page 329: Lighting Mechanisms (17.04)

    Lighting Mechanisms (17.04) Lighting (17.00) Lighting (17.00) Lighting Mechanisms (17.04) Headlamp Levelling (HID Only) Maintenance Headlamp Levelling Module-Renew Repair Operation Time (ROT) Item Code Headlamp Levelling Module-Renew 17.04.AB Removal 1. Remove IP unit from vehicle (see Workshop Manual procedure 01.12.AB Facia Assembly - LHD - Remove for Access and Refit).
  • Page 330 Lighting Mechanisms (17.04) Lighting (17.00) 17-4-2 Workshop Manual October 2005...

  • Page 331: Lighting Switches (17.05)

    Lighting Switches (17.05) Lighting (17.00) Lighting (17.00) Lighting Switches (17.05) Maintenance Master Lighting Switch Assembly-Renew Repair Operation Time (ROT) Item Code Master Lighting Switch Assembly- 17.05.AA Renew Removal 1. Release and remove driver's side lower instrument panel, clips (x7), disconnect air temperature pipe. 2.
  • Page 332 Electric Distribution/Electronic Control (18.00) Contents Wiring and Circuit Protection (18.01) ....18-1-2 Fuse Boxes .............. 1-2 Engine Bay Fuse/Relay Box........1-2 Central Electronics Module Fusebox....... 1-3 How to Read the Circuits........1-4 Wires..............1-4 Controller Area Network (CAN)......1-5 Media Oriented System Transport (MOST)..... 1-6 Connectors .............

  • Page 333: Electric Distribution/Electronic Control (18.00)

    Wiring and Circuit Protection (18.01) Electric Distribution/Electronic Control (18.00) Electric Distribution/Electronic Control (18.00) Wiring and Circuit Protection (18.01) Fuse Boxes Fuse Listings Engine Bay Fuse/Relay Box From the clean 12V output terminal of the battery disconnect switch, electrical power is distributed to three fuse boxes: •...

  • Page 334: Central Electronics Module Fusebox

    Wiring and Circuit Protection (18.01) Electric Distribution/Electronic Control (18.00) Headlamp wash pump (HID Only) Spare Centre console module/Sounder module/ Hazard switch Module - ABS/Key Reader and Steering angle sensors Diagnostic connectors/Brake pedal switch Spare High beam (RH) Alternator battery sensing High beam (LH) Heated front screen Drivers seat power (Heating)

  • Page 335: How To Read The Circuits

    Wiring and Circuit Protection (18.01) Electric Distribution/Electronic Control (18.00) How to Read the Circuits Boot Fusebox Below is a simple guide to what symbols mean on the circuit diagrams. For some of the symbols there are descriptions as to how they function. Wires Wire numbers have been deleted from the original engineering circuits.

  • Page 336: Controller Area Network (Can)

    Wiring and Circuit Protection (18.01) Electric Distribution/Electronic Control (18.00) The symbol for the screen is an oval with the wires that are to be screened inside it. The letters ‘SCR’ define the screen. 205 U MABC 05 Wire No. Colour MAB (Defines Screened) Size ‘CAN LS+’...

  • Page 337: Media Oriented System Transport (Most)

    Wiring and Circuit Protection (18.01) Electric Distribution/Electronic Control (18.00) Media Oriented System Transport Connectors (MOST) There are 2 types of interconnect shown on the circuits. Each connector is given a dedicated ‘C’ number. The A fibre optic carries out a similar function to that of a wire in number after the dash is the pin number, also known as the that it transmits data signals.
  • Page 338 Wiring and Circuit Protection (18.01) Electric Distribution/Electronic Control (18.00) Splices A splice is used where more than 2 wires that have the same requirement i.e. they need the same signal and meet in the same harness. In the example below the Front Position Lamp-LH and Front Side marker-LH require the same output signal from the CEM.
  • Page 339 Wiring and Circuit Protection (18.01) Electric Distribution/Electronic Control (18.00) Relays The high power current then flows through the high power normally open switch through the lamp and then to an earth. Another significant component in the circuits is a relay, this This can be seen more clearly in the diagram below.Lamp is in simple terms a switch that operates on the principal of Illuminates...

  • Page 340: Switches

    Wiring and Circuit Protection (18.01) Electric Distribution/Electronic Control (18.00) Lamps In a correctly protected circuit, the fuse is placed ‘Inline’ between the power source in this case the battery and the Below is the symbol for a light bulb, shown below the lamp.
  • Page 341 Wiring and Circuit Protection (18.01) Electric Distribution/Electronic Control (18.00) Motor Field Effect Transistor (FET) A field effect transistor (FET) is, in simplistic terms, a switch with no moving parts. The ‘switching’ is controlled by electronics and currents etc. rather than a physical switch being operated.

  • Page 342: Maintenance

    Wiring and Circuit Protection (18.01) Electric Distribution/Electronic Control (18.00) Maintenance 2. Position CD player, connect multiplug, install and torque tighten screws (x2). Transaxle Harness-Renew 3. Install centre stack assembly (see Workshop Manual procedure 15.01.CB Centre Stack Assembly - Remove Repair Operation Time (ROT) for Access &...

  • Page 343: Rear Bumper Harness-Renew

    Wiring and Circuit Protection (18.01) Electric Distribution/Electronic Control (18.00) 7. Disconnect multiplug to door mirror. 10. Install rear bumper (see Workshop Manual procedure 01.19.BA Cover Assembly - Rear Bumper - Renew). 8. Disconnect multiplug to door latch assembly. Tailgate Harness-Renew 9.

  • Page 344: Boot Fusebox Fuse-Each-Renew

    Wiring and Circuit Protection (18.01) Electric Distribution/Electronic Control (18.00) Boot Fusebox Fuse-Each-Renew Engine Bay Fusebox Fuse-Each-Renew Repair Operation Time (ROT) Repair Operation Time (ROT) Item Code Item Code Boot Fusebox Fuse-Each-Renew 18.01.KA Engine Bay Fusebox Fuse-Each-Renew 18.01.KC Removal Removal 1. Remove RH luggage compartment carpet (see 1.
  • Page 345 Wiring and Circuit Protection (18.01) Electric Distribution/Electronic Control (18.00) 3. Remove screws (x2) CEM to floor 4. Disconnect 8 multiplugs and remove CEM. 5. Remove relays (x2). 6. Remove fuses (x37) Installation 1. Install fuses. 2. Install relays (x2) 3. Connect multiplugs (x8) and install screws (X2) CEM to floor.

  • Page 346: Vehicle Control System (18.08)

    Vehicle Control System (18.08) Electric Distribution/Electronic Control (18.00) Electric Distribution/Electronic Control (18.00) Vehicle Control System (18.08) Customer Configuration There are certain modules / functions that the customer may Module Configuration or may not want reconfigured or enabled. Some of these Principles of Operation preferences are accessed through the ‘in-car’...

  • Page 347: Module Locations (Rhd)

    Vehicle Control System (18.08) Electric Distribution/Electronic Control (18.00) Module Locations (RHD) 18-2-2 Workshop Manual October 2005...
  • Page 348 Vehicle Control System (18.08) Electric Distribution/Electronic Control (18.00) October 2005 Workshop Manual 18-2-3...

  • Page 349: Module Locations (Lhd)

    Vehicle Control System (18.08) Electric Distribution/Electronic Control (18.00) Module Locations (LHD) 18-2-4 Workshop Manual October 2005...
  • Page 350 Vehicle Control System (18.08) Electric Distribution/Electronic Control (18.00) October 2005 Workshop Manual 18-2-5...
  • Page 351 Component Identification Code Description Sheet Number Code Description Sheet Number Code Description Sheet Number C0257 Airbag-Driver1 C0997 Coil Suppressor1 C2926 Earth Eyelet-Number Plate Lamps, Rear Sidemarkers C0251 Airbag-Passenger1 C0037 D/I Resistor-LH C2569 Earth Eyelet-Passenger Seat (Heater) C0261 Airbag-Passenger2 C0038 D/I Resistor-RH C2630 Earth Eyelet-PDC Module C0948...

  • Page 352: Component Identification Cont

    Component Identification Cont. Code Description Sheet Number Code Description Sheet Number Code Description Sheet Number C2276 FORWARD-ENGINE INLINE 2 Various C2207 Module-Bluetooth Receiver 18,19 C0919 Rear Sidemarker-LH C0419 Fresh/Recirc Actuator C0947 Module-Centre Console (Sim) C0918 Rear Sidemarker-RH C0355 Front Interior Lamp-LH C2522 Module-Centre Console (Trip Switches) C0068...
  • Page 353 Component Identification Cont. Code Description Sheet Number Code Description Sheet Number C2405 Sensor-Switch Buckle-Driver C2800 Switchpack-Seat-Manual 2 C1656 Sensor-Yawrate Acceleration C0775 Switchpack-Seat-Manual 3 C1930 Side Repeater-LH C2801 Switchpack-Seat-Manual 3 C1931 Side Repeater-RH C2992 Switch-Passenger Airbag Cut Off C0089 Socket-Accessory/Cigar Lighter C1541 Switch-PDC Disable 12,26...

  • Page 354: Circuit Diagrams - Index

    Circuit Diagrams - Index Engine Controller Active Restraint System Low Speed & High Speed CAN IVD / DSC / ABS Air Conditioning Heated Manual Electric Seat Wash Wipe (Inc H.I.D only Headlamp Wash) Auxiliary Driver Operated Systems Security System (Inc RHD only Tracker Drivers Door Passenger Door Parking Aid (Rear Sensors only)
  • Page 355 Circuit Diagrams...

  • Page 388: Electronic Features (19.00)

    Electronic Features (19.00) Contents Active Anti-Theft System (19.01) ......19-1-2 Alarm System Overview ......... 1-2 Component Descriptions ........1-2 Functional Description ........... 1-3 Overview – Alarm ..........1-3 General setting............1-3 Door open............. 1-3 Disable the Alarm ..........1-3 Reduced guard mode ..........1-3 Alarm Cycle ............

  • Page 389: Active Anti-Theft System (19.01)

    Active Anti-Theft System (19.01) Electronic Features (19.00) Electronic Features (19.00) Active Anti-Theft System (19.01) Alarm System Overview All alarm and central locking operations are controlled from within the Central Electronic Module (CEM). Communications with the Mass Movement Sensor, the Instrument Module, the Remote Key Less Entry Function and the Battery Backed Sounder are via data buses.
  • Page 390 Active Anti-Theft System (19.01) Electronic Features (19.00) Functional Description Alarm Cycle Overview – Alarm When the alarm has been activated there will be two outputs, these are listed below: The Vehicle Alarm System (VAS) will generate an audible Audible output device (Siren) and visual warning if the vehicle doors, bonnet or boot are opened without first disarming the system using an The audible alarm signal is generated by the battery backed...
  • Page 391 Active Anti-Theft System (19.01) Electronic Features (19.00) Remote Transmitter Integrated Passive Anti-Theft System (IPATS) The security system allows up to eight remote transmitters to be used for controlling the system functions. Description The remote transmitter come in packs of two. Each transmitter is associated with a series of numbers, which are IPATS (immobilisation system) is responsible for enabling / shown on a label located on the transmitter packaging.
  • Page 392 Active Anti-Theft System (19.01) Electronic Features (19.00) Key Programming Internet access required All vehicle keys are required to perform key programming. Using WDS. 1. Insert the first key to the ignition. 2. Select ‘Set up and Configuration’ on WDS. 3. Select either: •...
  • Page 393 Active Anti-Theft System (19.01) Electronic Features (19.00) 19-1-6 Workshop Manual October 2003...
  • Page 394 Electronic Features Modules (19.05) Electronic Features (19.00) Electronic Features (19.00) Electronic Features Modules Installation (19.05) 1. Install tyre pressure monitor module, install and tighten screws (x2). Maintenance 2. Connect multiplug to tyre pressure monitor module. Electronic Passenger Door Module- Renew Repair Operation Time (ROT) Item Code...
  • Page 395 Electronic Features Modules (19.05) Electronic Features (19.00) 19-2-2 Workshop Manual October 2003...
  • Page 396 Maintenance Remote Keyless Entry Module-Renew Repair Operation Time (ROT) Item Code Remote Keyless Entry Module-Renew 19.01.AF Removal 1. Remove DIP (see Workshop Manual procedure 13.01.AA Module - Driver Information - Renew). 2. Remove remote keyless entry module securing screws (x2) and multiplug (x1) Installation 1.

  • Page 397: Appendix & Glossary

    Appendix & Glossary Contents Diagnostic Ports ..........20-1-2 Fluids/Capacities..........20-1-3 Terms..............1-3 Special Tools - Pictorial Index ......20-1-4 Maintenance Schedules ........20-1-11 Torque Figures...........20-1-14 General Torque Figures........1-14 Vehicle Torque Figures Torque Conversion Tables1-15 October 2005 Workshop Manual 20-1-1...
  • Page 398 Diagnostic Ports Appendix & Glossary Appendix & Glossary Diagnostic Ports Diagnostic ports are provided for: • OBD II • Body - including 20-1-2 Workshop Manual October 2005...

  • Page 399: Fluids/Capacities

    Fluids/Capacities Appendix & Glossary Fluids/Capacities Capacities Europe Engine sump (incl. filter) 9.5 litres 16.7 pints 10.0 Qts Engine sump (excl. filter) 8.5 litres 15.0 pints 9.0 Qts Engine cooling system 12 litres 21 pints 14.4 Qts Screen washer reservoir 2.0 litres 3.5 pints 2.2 Qts Gearbox &...

  • Page 400: Special Tools - Pictorial Index

    Special Tools - Pictorial Index Appendix & Glossary Special Tools - Pictorial Index Part No./Description 303-F715-05 (Engine/Subframe Trolley Adaptors) Part No./Description 303-F715 (Multi-purpose Trolley x2) 205-521 (Rear Subframe Bush Removal) 303-F715-06 (Trolley Link Bars) 36-10-013 205-791 (Rear Subframe Bush Removal (use with 205- 521)) 303-F715-04 (Rear Subframe Trolley Adaptors) 205-792 (Rear Subframe Receiver Cup)
  • Page 401 Special Tools - Pictorial Index Appendix & Glossary Part No./Description Part No./Description 205-793 (Rear Subframe Bush Installer) 303-667 (Clutch Alignment) 310-040 (Fuel Pipe Disconnect Tool) 501-108 (IP Alignment Pins) 310-134 (Filler Neck Disconnect Tool) 501-073A (Airbag Simulators) 310-140A (Fuel Pump Install/Remove) 501-103 (Side Airbag and Pretensioner simulators) October 2005 Workshop Manual...
  • Page 402 Special Tools - Pictorial Index Appendix & Glossary Part No./Description Part No./Description 501-104 (Trim Removal) 43-27750 (MOST Tester) 412-026 (Quick Disconnect Tool) 43-10047 (Wiring Harness Repair Kit) 412-132 (Quick Disconnect Tool) 412-038 (Quick Disconnect Tool) (Break-out Box to be used in conjunction with PCM II Test Lead - 43-10048) Image to follow 412-040 (Quick Disconnect Tool)
  • Page 403 Special Tools - Pictorial Index Appendix & Glossary Part No./Description Part No./Description 204-523 (Ball Joint Splitter) 501-115 (Front Veneer Removal) 418-583 (Oxygen Sensor Diagnostic Lead) 206-100 (Brake Hose Install) 204-524 (Front Suspension Support) 501-112 (Wiper Linkage to Wiper Motor) Image to follow 501-F111 (Door Service Trolley) 206-103 (Handbrake Cable Removal) October 2005...
  • Page 404 Special Tools - Pictorial Index Appendix & Glossary Part No./Description Part No./Description 501-F116 (IP Removal) 303-1185 (Flywheel Locking Tool) 303-1186 (Crankshaft Vibration Damper Remover) 204-321-01 (Spring Compressor Adaptor Plate) 303-1187 (Oil filter Wrench) 303-021-02 (Engine Support Brackets) 20-1-8 Workshop Manual October 2005...
  • Page 405 Special Tools - Pictorial Index Appendix & Glossary Part No./Description Part No./Description 303-1188 (Sump Filter Plug Tool) 303-749 (Engine Lifting Brackets) Image to follow 303-750 (Crankshaft Front Oil Seal Installer) 303-1189 (Crankshaft Rear Oil Seal Installer/Remover) Image to follow 303-F715-07 (Trolley Adaptor) 303-1190 (Crankshaft Front Oil Seal Remover) 308-641 (Gear Shift Locking Tool) 303-536 (Engine Lifting Brackets)
  • Page 406 Special Tools - Pictorial Index Appendix & Glossary Part No./Description 308-642 (Gear Shift Cable Release Tool) 310-155 (Fuel Tank Drain Adaptor) 20-1-10 Workshop Manual October 2005...

  • Page 407: Maintenance Schedules

    Maintenance Schedules Appendix & Glossary Maintenance Schedules 1000mls 10000mls 20000mls 1500km 16000km 32000km 3 months 12 months 24 months Pre-maintenance Pre-Maintenance Road Test Evaluation. Install vehicle protection kit and wing covers. Check Bulletins/Field Service Actions/Recall Status. Fluids, Filters and Leaks Checks Check/top-up engine oil level.
  • Page 408 Torque Figures Appendix & Glossary 1000mls 10000mls 20000mls 1500km 16000km 32000km 3 months 12 months 24 months Mechanical Function Checks Lubricate the bonnet secondary latch. Check security of the bonnet catch. Check that the secondary catch moves freely over its whole travel and returns smartly under spring pressure. Lubricate the upper portion of the door seals.
  • Page 409 Torque Figures Appendix & Glossary 1000mls 10000mls 20000mls 1500km 16000km 32000km 3 months 12 months 24 months Wheels and Tyre Checks Check for correct tyre size, type and orientation. Check and report tyre tread depth. Check tyres for uneven/excessive wear or damage. Check/adjust tyre pressures.
  • Page 410 Torque Figures Appendix & Glossary Torque Figures General Torque Figures Nominal Applied Torque (Nm) Dia. 4.6 & 4.82 8.8/8 9.8/9 10.9 & 10.9/10 12.9/12 Stamped on bolt head Mean +/- Mean +/- Mean +/- Mean Mean +/- 10.4 10.4 11.8 15.2 17.5 19.5...

  • Page 411: Torque Conversion Tables

    Torque Conversion Tables Appendix & Glossary Vehicle Torque Figures Torque Conversion Tables Newton Metres to Pounds Feet Pounds Feet 0.74 1.47 2.21 2.95 3.69 4.42 5.16 5.90 6.64 7.38 8.11 8.85 9.59 10.33 11.06 11.80 12.54 13.28 14.01 14.75 15.49 16.23 16.96 17.71...
  • Page 412 Torque Conversion Tables Appendix & Glossary Newton Metres to Pounds Feet (Continued) Pounds Feet 295.03 295.76 298.50 297.24 297.98 298.71 299.45 300.19 300.93 301.68 302.40 303.14 303.88 304.61 305.35 306.09 306.83 307.56 308.30 309.04 309.78 310.51 311.25 311.99 312.73 313.46 314.20 314.94 315.68 316.41 317.15 317.89 318.63 319.36 320.10 320.84 321.58 322.32 323.05 323.79 324.53 325.27 326.00 326.74 327.48 328.22 328.95 329.68 330.43 331.17 331.90 332.64 333.38 334.12 334.35 335.59 336.33 337.07 337.80 338.54...
  • Page 413 Torque Conversion Tables Appendix & Glossary Newton Metres to Pounds Feet (Continued) Pounds Feet 590.79 591.53 592.26 593.00 593.74 594.48 595.21 595.95 596.58 596.68 597.43 598.16 598.90 599.64 600.38 601.11 601.85 602.59 603.33 604.06 604.80 605.54 606.28 607.01 607.75 608.49 609.23 609.96 610.70 611.44 612.18 612.91 613.65 614.39 615.13 615.86 616.60 617.34 618.08 618.81 619.55 620.29 621.03 621.77 622.50 623.24 623.98 624.72 625.45 626.19 626.93 627.67 628.40 629.14 629.68 630.62 631.35 632.09 632.83 633.57...
  • Page 414 Torque Conversion Tables Appendix & Glossary Pounds Feet to Newton Metres (Continued) Newton Metres 271.16 272.52 273.88 275.23 276.59 277.94 279.30 280.65 282.01 283.37 284.72 286.08 287.43 288.79 290.15 291.50 292.86 294.21 295.57 296.92 298.28 299.64 300.99 302.35 303.70 305.06 306.42 307.77 309.13 310.48 311.84 313.19 314.55 315.91 317.26 318.62 319.97 321.33 322.68 324.04 325.40 326.75 328.11 329.46 330.82 332.18 333.53 334.89 336.24 337.60 338.95 340.31 341.67 343.02 344.38 345.73 347.09 348.45 349.80 351.16...
  • Page 415 Torque Conversion Tables Appendix & Glossary Pounds Feet to Newton Metres (Continued) Newton Metres 813.49 814.85 816.20 817.56 818.91 820.27 821.63 822.98 824.34 825.69 827.05 828.41 829.76 831.12 832.47 833.83 835.18 836.54 837.90 839.25 840.61 841.96 844.32 844.68 848.03 847.39 848.74 850.10 851.45 852.81 854.17 855.52 856.88 858.23 859.59 860.94 862.30 863.68 865.01 868.37 867.72 868.08 870.44 871.79 873.15 874.50 875.86 877.21 878.57 879.93 881.28 882.64 883.99 885.35 886.71 888.06 689.42 890.77 892.13 893.48...

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