Aston Martin DB9 Workshop Manual

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Workshop Manual

Issue 7

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Page 1 Workshop Manual Issue 7...
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
DB9 Workshop Manual Contents Introduction Driveline (05.00) Welcome ............... i-i-iv Driveshaft (05.01) ..........5-1-2 Safety Precautions........... i-i-v Rear Drive System (05.02) ........5-2-1 Lifting and Jacking..........i-i-vii Halfshafts (05.05)..........5-5-1 Vehicle Recovery ..........i-i-viii Brake System (06.00) Vehicle Identification Number ....... i-i-ix Description ............
Page 4 Vehicle Entertainment (15.00) Audio System ............. 15-1-1 Vacuum Distribution (16.00) Body Vacuum System (16.01)......16-1-1 Lighting (17.00) Front Lights (17.01) ..........17-1-2 Interior Lighting (17.02) ........17-2-1 Rear Lights (17.03) ..........17-3-1 Lighting Mechanisms (17.04) ......17-4-1 Electric Distribution/Electronic Control (18.00) Wiring and Circuit Protection (18.01) ....
Page 5 Introduction Contents Welcome..............I-I-VI Chapters ..............I-VI Chapter Navigation ..........I-VI Numbering ............I-VI Special Tools............I-VI Location References..........I-VI Warnings, Cautions and Notes......I-VI Repairs and Replacements ........I-VI Safety Precautions ..........I-I-VII Battery Disconnection .......... I-VII Air Conditioning (A/C) System......I-VII Chemical Handling and Storage......
Page 6: Introduction
Chapters orientation of the assembly when installed in the vehicle. The DB9 suite of manuals incorporate a new chapter structure. Warnings, Cautions Each chapter in this workshop manual is associated with a 4 and Notes digit number, i.e.
Page 7: Safety Precautions
Safety Precautions Introduction Safety Precautions All service workshops are a source of potential danger and repair work should only be performed by technically trained staff following procedures detailed in this manual. A safety conscious approach to the performance of all service procedures must be observed at all times.
Page 8: Chemical Handling And Storage
Safety Precautions Introduction Chemical Handling and Storage acids, adhesives, antifreeze, brake fluids, coolants, grease, oil, paint, resin and solvents. Exposure to some chemicals WARNING through direct contact or inhalation can cause injury or OBEY ALL HANDLING AND SAFETY INFORMATION death. THAT IS ON CONTAINERS AND LABELS.
Page 9: Fire Precautions
Safety Precautions Introduction Fire Precautions The workplace should have sufficient washing facilities and materials to protect the the skin available. WARNING Health Protection Precautions MAKE SURE THAT AN APPLICABLE TYPE OF FIRE EXTINGUISHER IS LOCATED NEAR THE WORK AREA. WARNING WARNING LONG AND FREQUENT CONTACT WITH USED KEEP OILS, SOLVENTS AND COMBUSTIBLE...
Page 10: Lifting And Jacking
Lifting and Jacking Introduction Lifting and Jacking The vehicle may also be jacked with the jack placed on the front subframe, front crossmember. Safety WARNING OBEY THE LOCAL WORKSHOP REGULATIONS WHEN YOU TOW OR LIFT A VEHICLE. WARNING DO NOT USE A JACK TO HOLD A VEHICLE WHEN Front Crossmember YOU DO WORK UNDER IT.
Page 11: Vehicle Recovery
Vehicle Recovery Introduction Vehicle Recovery Rear Suspended Tow 1. Set the steering in the ‘straight ahead’ position. General 2. Remove the ignition key from the ignition. Ensure the steering is locked in the straight ahead position. The preferred method of vehicle recovery is by a flat bed, 3.
Page 12: Vehicle Identification Number
Identification Numbers Introduction Identification Numbers Vehicle Identification Number (VIN) The Vehicle Identification Number (VIN) is a 17 character number which uniquely identifies the vehicle and gives important data about the build site, date and initial configuration of the vehicle. VIN Location The VIN number is stamped / plated in the locations that follow: Under the bottom edge of the windscreen.
Page 13: Engine Number
Identification Numbers Introduction Engine Number Gearbox Number Automatic Gearbox The engine number is stamped on the LH side of the engine block. The automatic gearbox number plate is located on the LH side of the gearbox. Manual Gearbox To follow. Issue 7, September 2011 Workshop Manual I-I-XIII...
Page 14 Identification Numbers Introduction I-I-XIV Workshop Manual Issue 7, September 2011...
Page 15: Body System (01.00)
Body System (01.00) Contents Body Structure (01.01)...........1-1-3 Maintenance............9-1 Door Mirrors............9-1 Overview ..............1-3 Front End (01.02) ...........1-2-1 Removal.............. 9-1 Front Wings ............2-1 Installation ............9-1 Specifications............2-1 Seating (01.10)............. 1-10-1 Maintenance............2-1 Description............10-1 Front Wing ............2-1 Heated Seats ............
Page 16 Rear Quarter Glass (Volante) ........11-7 Maintenance ............17-2 Remove .............11-7 Roof..............17-2 Installation ............11-9 Removal ............17-2 Instrument Panel (IP) (01.12)......1-12-1 Installation ............17-2 Specifications ............12-1 Roof Material ............17-3 Maintenance ............12-1 Removal ............17-3 IP .................12-1 Installation ............17-4 Removal ............12-1 Weather Seals ............17-8 Installation ............12-3 Removal ............17-8 Installation ............17-8 Veneer Bezel for the Instrument Panel (IP)
Page 17: 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 18 Body Structure (01.01) Body System (01.00) 1-1-4 Workshop Manual Issue 7, September 2011...
Page 19: Overview
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 20 Body Structure (01.01) Body System (01.00) 1-1-4 Workshop Manual Issue 6, March 2010...
Page 21: Front End (01.02)
Front End (01.02) Body System (01.00) Body System (01.00) Front End (01.02) Maintenance Front Wing Front Wings Repair Operation Time (ROT) Specifications Item Code Front Wing Renew (LH) 01.02.KB (RH) 01.02.LB Removal 1. Disconnect the vehicle battery. 2. Remove the wing top nut. Wing Standard (mm) Item Nominal gap...
Page 22 Front End (01.02) Body System (01.00) 4. Disconnect the side repeater lamp wiring harness plug. 7. Remove bolts (x3). 5. Disconnect the wing from the bumper (Refer to ’Front Bumper’, page 1-19-1). 6. Remove the slam panel (bolts x12). Remove the front grill bolt (x2).
Page 23 Front End (01.02) Body System (01.00) 8. Loosen bolts (x2). Installation 1. Place the wing to the body. 2. Locate: • The wing top stud • The rear lower wing to the loosened bolts 3. Install the wing lower edge clips and bolt. 4.
Page 24 Front End (01.02) Body System (01.00) 6. Install the slam panel. 01-02-007 7. Check wing alignment. Refer to specifications. Adjust if required. 8. Torque all wing fixings. 9. Connect the side repeater lamp wiring harness plug. 10. Install the road wheel and road wheel arch liner (Refer to ’Torque Tightening of Road Wheel Nuts’, page 4-4- 11.
Page 25: Body Closures (01.03)
Body Closures (01.03) Body System (01.00) Body System (01.00) Body Closures (01.03) Boot Lid Specifications Doors Boot Standard (mm) Item Door Standard (mm) Nominal gap Item Tolerance ±0.75 ±1.0 Nominal gap 3.00 3.00 3.75 Flush -0.5 Tolerance ±0.75 ±1.0 ±1.0 ±...
Page 26: Maintenance
Body Closures (01.03) Body System (01.00) Maintenance 5. Lift the door off the support studs and withdraw the door enough to gain access to the door wiring harness Doors plug. Disconnect the wiring harness plug. Repair Operation Time (ROT) Item Code Remove and reinstall 01.03.EA...
Page 27: New Door Assembly
Body Closures (01.03) Body System (01.00) New Door Assembly 5. Connect the vehicle battery. Warning Repair Operation Time (ROT) Never touch the door lock linkage with electrical Item Code power available to the door. The window mechanism Remove and install 01.03.CB can move and trap hands, arms, etc.
Page 28: Boot Lid
Body Closures (01.03) Body System (01.00) Boot Lid 4. Lower the boot lid. Check for correct alignment and readjust if required. Repair Operation Time (ROT) 5. Fully raise the boot lid. Torque the hinge bolts to 25 Item Code Remove and reinstall 01.03.BB Removal Warning...
Page 29: Bonnet
Body Closures (01.03) Body System (01.00) Bonnet Repair Operation Time (ROT) Item Code Remove and reinstall 01.03.AB Removal Warning The bonnet is heavy. Removal is a two person operation. 1. Open the bonnet. 2. Disconnect the windscreen wash pipe. 3. Slightly loosen the bolts (x4) that secure the bonnet to the hinge.
Page 30 Body Closures (01.03) Body System (01.00) 1-3-6 Workshop Manual Issue 3 October 2007...
Page 31: 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 mouldings 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 32: Roof Trim
Interior Trim (01.05) Body System (01.00) Roof Trim Removal 1. Remove (pull away) the cant rail. The cant rail is held in by ‘FirTrees’. The front of the cant rail is held in place by the ‘IP’. Pull the cant rail away from the back first then pull the front out from the ‘IP’.
Page 33: Door Trim
Interior Trim (01.05) Body System (01.00) Door Trim 5. Remove the door mirror cheater panel. Removal 1. Lower the door glass fully. 2. Disconnect vehicle battery. 3. Release the door handle (Bolts x2). 6. Remove outer chrome waist rail trim. 4.
Page 34: Installation
Interior Trim (01.05) Body System (01.00) Installation 8. Remove the door trim panel screws (x6). Withdraw the door trim panel to gain access to the window and mirror 1. Place the door trim panel to the door and connect the switches.
Page 35: Rear Trim
Interior Trim (01.05) Body System (01.00) Rear Trim Removal (Coupe) Issue 3 October 2007 Workshop Manual 1-5-5...
Page 36: Install (Coupe)
Interior Trim (01.05) Body System (01.00) Install (Coupe) Install the trim in reverse order to remove. Torque seat belt mounts to 35 Nm. Removal (Volante) 1. Remove the seat bases. 2. Remove the seat backs. Pull off and up to remove the head support. Remove screws (x2 (Bottom) and x2 (top)).
Page 37: Boot Trim
Interior Trim (01.05) Body System (01.00) Boot Trim Removal 1. Remove the boot weather seal. 2. Remove the boot trim in the following order detailed above. Item Fixings Item Fixings Fir trees Fir trees Fir trees Fir trees Fir trees Fir trees Fir trees Fir trees...
Page 38 Interior Trim (01.05) Body System (01.00) 1-5-8 Workshop Manual Issue 3 October 2007...
Page 39: Exterior Trim (01.08)
Exterior Trim (01.08) Body System (01.00) Body System (01.00) Exterior Trim (01.08) 5. Remove the chrome trim screws (x18). Remove the chrome trim. Maintenance Support the trim as it is removed. Side Trim Removal 1. Remove the trim panel. Remove the top / bottom screws (x2). Remove the outer panel.
Page 40: Sill Trim
Exterior Trim (01.08) Body System (01.00) Sill Trim 5. Unclip the sill trim from the vehicle body. Withdraw the sill trim. Remove Installation 1. Remove the front and rear road wheel arch liners 1. Offer the sill trim to the vehicle. sufficiently to gain access.
Page 41 Exterior Trim (01.08) Body System (01.00) 5. Install (x3) screws and (x2) scrivnuts. 6. Install the front and rear road wheel arch liners. Issue 3 October 2007 Workshop Manual 1-8-3...
Page 42 Exterior Trim (01.08) Body System (01.00) 1-8-4 Workshop Manual Issue 3 October 2007...
Page 43: Mirrors (01.09)
Mirrors (01.09) Body System (01.00) Body System (01.00) Mirrors (01.09) Installation 1. Place the mirror into position. Install bolts (x2). Specifications The spring washer goes between the mirror bracket and the door. On the front bolt of each mirror, ensure that the plain Torque Figures washer goes between the bolt head and the mirror bracket.
Page 44 Mirrors (01.09) Body System (01.00) 1-9-2 Workshop Manual Issue 3 October 2007...
Page 45: Seating (01.10)
Seating (01.10) Body System (01.00) Body System (01.00) Seating (01.10) Maintenance Front Seat - Remove and Install Description Repair Operation Time (ROT) The front seats are installed with the following features: Item Code • Integral side airbags Front Seat - Remove and Install 01.10.AA •...
Page 46: Install
Seating (01.10) Body System (01.00) Seat Base Control Motors 5. Remove the seat assembly. Install The seat base control motors are an integral part of the seat base. 1. Place the seat in the vehicle. Front Seat Squab Cover Assembly (Each, 2.
Page 47: Seat Module Calibration
Seating (01.10) Body System (01.00) Seat Module Calibration Rear Seats Removal (Coupe) This mode allows the seat module to learn its position. The seat needs to know exactly where it is to electronically prevent seat movement into certain areas within the mechanical seat movement envelope.
Page 48: Removal (Volante)
Seating (01.10) Body System (01.00) Removal (Volante) 7. Disconnect the electrical connector for the pump. 8. Remove the pump assembly. 1. Remove the seat bases. Pull off. Install 1. Connect the the air hose to the pump. 2. Put the air valve in position into the inlay. 3.
Page 49: Lumbar Bladder For The Front Seat (From 08My) - Remove And Install
Seating (01.10) Body System (01.00) Lumbar Bladder for the Front Seat (From 08MY) - Remove and Install Repair Operation Time (ROT) Item Code Lumbar Bladder for the Front Seat 01.10.EK (From 08MY) - Remove and Install Remove 1. Remove the applicable front seat (Refer to ’Front Seat - Remove and Install’, page 1-10-1).
Page 50 Seating (01.10) Body System (01.00) 1-10-6 Workshop Manual Issue 4 November 2008...
Page 51: 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 Maintenance Glass Regulator Power to the door window regulator motor is available when the ignition switch is at position ‘0’ and is supplied, through Repair Operation Time (ROT) a thermal cut-out, to the left and right window switches.
Page 52: Installation
Glass, Frame and Mechanism (01.11) Body System (01.00) 6. Release nuts (x4). Withdraw the window regulator from 2. Install nuts. Torque nuts (x3) M6 to 9 Nm. and (x1) M10 the door. 10-15 Nm. Installation 3. Install the window regulator motor (screws x3). Torque 1.
Page 53: Door Glass
Glass, Frame and Mechanism (01.11) Body System (01.00) Door Glass 7. Align the door glass. Ensure the following when installing a new door glass. Repair Operation Time (ROT) • The glass is flush with the mirror trim edge Item Code Door Glass Renew 01.11.BB 01.11.HB...
Page 54: Installation
Glass, Frame and Mechanism (01.11) Body System (01.00) 3. Remove the door handle trim plate and disconnect the 5. Disconnect the vehicle battery. release cable. WARNING PUT ON PROTECTIVE GLOVES AND EYE PROTECTION WHEN YOU HOLD THE GLASS COMPONENTS. THE GLASS CAN BREAK EASILY AND CAUSE INJURY. 6.
Page 55 Glass, Frame and Mechanism (01.11) Body System (01.00) F ront R ear 4. Connect the inner release cable and install the door handle trim plate. 5. Install the door handle Torque bolts (x2) to 9 Nm. Issue 4 November 2008 Workshop Manual 1-11-5...
Page 56: Door Glass Setup
Glass, Frame and Mechanism (01.11) Body System (01.00) 6. Install the door outer weather strip. 7. Connect the vehicle battery. 8. Check that the door glass operates correctly. Perform the ‘Door glass Setup’ procedure. Door Glass Setup 1. Sit in the driver’s seat. 2.
Page 57: Rear Quarter Glass (Coupe)
Glass, Frame and Mechanism (01.11) Body System (01.00) Rear Quarter Glass (Coupe) 4. Disconnect the vehicle battery. Repair Operation Time (ROT) Item Code Rear Quater Glass Renew 01.11.LB 01.11.MB Remove 1. Pull the door sealing rubber away from the rear quarter glass.
Page 58 Glass, Frame and Mechanism (01.11) Body System (01.00) 5. Remove the seat belt top mount. 6. Remove the rear 1/4 panel. bolts x2 fir trees x3 9. Disconnect the glass regulator wiring harness plug. 10. Power up the glass regulator to line up the two glass securing screws through the two holes in the top bracket.
Page 59: Installation
Glass, Frame and Mechanism (01.11) Body System (01.00) Installation 1. Install the glass regulator. Install the nut to the top of the glass regulator. Do not torque. 12. Power the glass regulator down. 13. Remove the nuts (x2) that secure the bottom of the glass regulator.
Page 60 Glass, Frame and Mechanism (01.11) Body System (01.00) 7. Adjust the lower mountings (2) to achieve the 5 mm gap between the glass and the edge of the vehicle body. 10-15 Nm. When adjusted, torque the outer nuts to 10-15 Nm. 8.
Page 61: Instrument Panel (Ip) (01.12)
Instrument Panel (IP) (01.12) Body System (01.00) Body System (01.00) Instrument Panel (IP) (01.12) 11.Remove the A/C evaporator pipes. Cap the open ends of all pipes. Specifications Torque Figures 12. Disconnect the wiring harness plugs. Description lb. / ft. Remove the bonnet pull lever to gain access to L/H harness IP Mountings 22.5 plugs.
Page 62 Instrument Panel (IP) (01.12) Body System (01.00) 13.Manual Gearbox Only. Remove the gear-lever. 13.1 Disengage the manual shift control cables (x2). 13.2 Remove screws (x6) that secure the gear lever pivot block. Withdraw the gear lever. 14. Remove, L/H and R/H, bolts securing the IP to vehicle. 14.1 Bolts (x6 L/H and R/H).
Page 63: Installation
Instrument Panel (IP) (01.12) Body System (01.00) 14.3 Glue pot bolts (x2). 17.Move the IP rearwards sufficient to gain access to the heater pipes. Disconnect the heater pipes. One person to open the spring clip from inside the vehicle and one person to pull the pipes off from inside the engine bay.
Page 64 Instrument Panel (IP) (01.12) Body System (01.00) Install bolts (x2 L and R/H). Do not tighten. Bolts (x2 L and R/H). Torque bolts to 22.5 Nm. Install the glue pot bolts (x2). Do not tighten. 7. Install the heater blower to the bulkhead bolt. Torque to 10-14 Nm.
Page 65: Veneer Bezel For The Instrument Panel (Ip) - Remove And Install
Instrument Panel (IP) (01.12) Body System (01.00) Veneer Bezel for the Instrument Panel (IP) - 4. Disconnect the electrical connectors from each of the four transmission control switches. Remove and Install Repair Operation Time (ROT) Item Code Veneer Bezel for the Instrument Panel 01.12.AV (IP) Remove...
Page 66 Instrument Panel (IP) (01.12) Body System (01.00) 7. Disconnect the two electrical connectors from the 10. Remove the right heater vent. navigation display screen. 11. Remove the three Torx screws that attach the left heater 8. Remove the veneer bezel. vent to the veneer bezel.
Page 67 Instrument Panel (IP) (01.12) Body System (01.00) 13. Remove the four Torx screws that attach the ignition 16. Remove the four transmission switches from the veneer switch module to the veneer bezel. bezel. 14. Remove the ignition switch module. 17. Remove the 12 Torx screws that attach the transmission switch retainer to the veneer bezel.
Page 68 Instrument Panel (IP) (01.12) Body System (01.00) 19. Release the electrical connector from the clip that 22. Cut the cable tie that attaches the wiring harness to the attaches it to the mechanism for the navigation display navigation display screen. screen.
Page 69 Instrument Panel (IP) (01.12) Body System (01.00) 25. Release the holder for the navigation display screen 28. Remove the navigation display screen. from the mechanism for the navigation display screen. 29. Remove the four screws that attach the veneer bezel 26.
Page 70 Instrument Panel (IP) (01.12) Body System (01.00) 31. Remove the four screws that attach the mechanism for 2. Install but do not fully tighten, the four screws that the navigation display screen to the veneer bezel. attach the mechanism for the navigation display screen to the veneer bezel.
Page 71 Instrument Panel (IP) (01.12) Body System (01.00) 5. Install the navigation display screen. 8. Install the holder for the navigation display screen to the mechanism for the navigation display screen. 6. Put the holder for the navigation display screen into position.
Page 72 Instrument Panel (IP) (01.12) Body System (01.00) 11. Install a new cable tie to attach the wiring harness to the 14. Install the electrical connector to the clip that attaches it navigation display screen. to the mechanism for the navigation display screen. 12.
Page 73 Instrument Panel (IP) (01.12) Body System (01.00) 17. Install the transmission switch retainer to the veneer 20. Put the four transmission switches into the correct bezel. positions. 21. Install the ignition switch module. 18. Install and tighten the 12 Torx screws that attach the transmission switch retainer to the veneer bezel.
Page 74 Instrument Panel (IP) (01.12) Body System (01.00) 23. Install the left side heater vent. 26. Install and tighten the three Torx screws that attach the right side heater vent to the veneer bezel. 24. Install and tighten the three Torx screws that attach the left side heater vent to the veneer bezel.
Page 75: Install
Instrument Panel (IP) (01.12) Body System (01.00) 29. Connect the electrical connector to the ignition switch 32. Attach the veneer bezel with the four clips. module. 33. Do the battery connection procedure (Refer to 30. Connect the electrical connector to the ignition switch Workshop Manual procedure 14.01.CA - Battery module.
Page 76 Instrument Panel (IP) (01.12) Body System (01.00) 3. Remove the two screws that attach the armrest to the 6. Remove the two Torx bolts that attach the front of the centre console. armrest to the bracket. Figure E-01-12-DA-02 Figure E-01-12-DA-07 4.
Page 77 Instrument Panel (IP) (01.12) Body System (01.00) 9. Remove the two screws that attach the centre console 12. Release the centre console panel from the body. panel to the body. Figure C-01-12-DA-17 Figure C-01-12-DA-13 13. Disconnect the electrical connector from each of the four switches.
Page 78 Instrument Panel (IP) (01.12) Body System (01.00) 2. Connect the electrical connector to each of the four 6. Install the two screws that attach the centre console switches. panel to the body. Figure C-01-12-DA-18 Figure C-01-12-DA-13 3. Install the gear knob. 7.
Page 79 Instrument Panel (IP) (01.12) Body System (01.00) 10. Remove the four screws that attach the rear console to 14. Tighten the two Torx screws at the front of the armrest. the body. E-01-04-BB-04 Figure E-01-12-DA-07 11. Move the rear console to let the armrest move below. 15.
Page 80 Instrument Panel (IP) (01.12) Body System (01.00) 18. Install the trim piece onto the armrest. 21. Install the rear console lower-panel. Figure E-01-04-BB-03 Figure E-01-12-DA-01 22. Install the rear console lower-panel into the two fir tree 19. Move the rear console to the initial position. clips.
Page 81: 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.
Page 82: Specifications
Handles and Lock Mechanisms (01.14) Body System (01.00) Specifications Torque Figures Description lb. / ft. Door handle Latch Maintenance Door Handle / Latch Unit Repair Operation Time (ROT) Item Code Door Catch and Outer Lock 01.14.MB 01.14.NB 4. Remove the door trim (Refer to ’Door Trim’, page 1-5- Removal 5.
Page 83: Installation
Handles and Lock Mechanisms (01.14) Body System (01.00) Installation 1. Install the outer door handle. The outer door handle is reversible (installs to L/H and R/H). Caution Ensure the Inertia block is in the ‘Floating’ position. Ensure that the fir tree on the release cable is removed. 8.
Page 84 Handles and Lock Mechanisms (01.14) Body System (01.00) 2. Connect the outer, inner and lock cables to the latch. 4. Install the latch (screws x3). Torque to 9 Nm. Insert the lock and latch assembly into position. Feed the inner cable through the hole provided in the door. Do not push the inner cable when it is hanging from the door.
Page 85: 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 washer system consists of the following components: • Wipers and washers • Reservoir and washer pump • Mounting arm and pivot shaft •...
Page 86: Headlamp Washing
Wipers and Washer System (01.16) Body System (01.00) Headlamp Washing Maintenance Driver's Side Wiper Blade - Remove and The headlamp washers operate once per ignition cycle and Install (12MY onward) are activated the first time the window washers are operated. Repair Operation Time (ROT) Headlamp washing is only available when the headlamps Item...
Page 87: Install
Wipers and Washer System (01.16) Body System (01.00) Passenger’s Side Wiper Blade - Remove 3. Remove the wiper blade. and Install (12MY onward) Repair Operation Time (ROT) Item Code Passenger’s Side Wiper Blade - Remove 01.16.AG and Install (12MY onward) Remove 1.
Page 88: Install
Wipers and Washer System (01.16) Body System (01.00) Windscreen Reservoir and Motor Install Assembly - Remove and Install 1. Put the wiper blade into position. Repair Operation Time (ROT) Item Code Windscreen Reservoir and Motor 01.16.DA Assembly - Remove and Install Remove 1.
Page 89: Install
Wipers and Washer System (01.16) Body System (01.00) 8. Connect the electrical connector for the windscreen 20. Disconnect the electrical connector for the level sensor. washer motor. 21. Remove level sensor and seal from reservoir. 9. Raise the vehicle on the lift. Install 10.
Page 90: Install
Wipers and Washer System (01.16) Body System (01.00) 11. Remove the rear-lower reservoir fixing. 3. Remove the wiper arms. Note the position of the wiper arms on the glass for installation. 12. Lower the vehicle on the lift. Note: Do not remove the nut that secures the idle arm to 13.
Page 91: Installation
Wipers and Washer System (01.16) Body System (01.00) 10. Disconnect the wiper linkage from the wiper motor (bolt x1). Withdraw the wiper motor. 8. Remove the wiper assembly mounting bolts and allow the wiper assembly drop sufficiently to access the wiper motor bolts.
Page 92: Wiper Arms
Wipers and Washer System (01.16) Body System (01.00) 9. Install the inlet manifolds (Refer to ’Inlet Manifold’, page 3-1-7). Torque bolt to 6 Nm. 10. Connect the vehicle battery. Wiper Arms Repair Operation Time (ROT) Item Code Wiper Arm Renew 01.16.KG 01.16.LB Removal...
Page 93: Installation
Wipers and Washer System (01.16) Body System (01.00) Installation 1. Install the wiper arms. Position the wiper arms as per their position on removal. Passenger Arm Torque M10 nut to 24 Nm. Torque M6 (x4) nuts to 6 Nm. Driver Arm Torque M8 nut to 17 Nm.
Page 94 Wipers and Washer System (01.16) Body System (01.00) 1-16-10 Workshop Manual Issue 7, September 2011...
Page 95: Convertible Roof (01.17)
Convertible Roof (01.17) Body System (01.00) Body System (01.00) Convertible Roof (01.17) Description The convertible roof system comprises an electrically driven hydraulic pump and six hydraulic rams, four for raising and lowering the roof and two for raising and lowering the tonneau cover. The pump is powered via either the 'Roof Up' or Roof Down' relay.
Page 96: Maintenance
Convertible Roof (01.17) Body System (01.00) Maintenance 6. Manually raise the tension bow to 90°. For access to the hydraulic pipes and wiring harness plugs. Roof With the roof in the raised position and the tension bow in Removal the 90° position the hydraulic rams have the minimum amount of hydraulic oil in them.
Page 97: Roof Material
Convertible Roof (01.17) Body System (01.00) Roof Material 7. Remove the rear roof seal. WARNING DO NOT PLACE ANY OBJECTS ON THE TOP OF THE DEPLOYABLE ROLLBAR COVERS BEHIND THE REAR SEAT BACKS. WARNING DO NOT ALLOW ANY PERSON TO SIT ON THE DEPLOYABLE ROLLBAR COVERS AT ANY TIME.
Page 98: Installation
Convertible Roof (01.17) Body System (01.00) 11.2 Remove the three tension cord mounts. 17. Remove the two side cable securing clips (two each side) and withdraw the side tension cables through the roof lining. Re m ove Ca ble 01-01-213 12.
Page 99 Convertible Roof (01.17) Body System (01.00) 3. Roll the roof material to the 1st cross bar. 6. Roll the roof material to the 2nd frame cross bar. 4. Remove the sticky strip protection and locate to the first 7. Repeat step 6 and 7. cross bar.
Page 100 Convertible Roof (01.17) Body System (01.00) 12. Install the window tension cord (if not install). 12.1 Thread the tension cord through the center hole. 10. Place the material with the sticky pads into position. Remove the sticky pads protection and affix to the header rail.
Page 101 Convertible Roof (01.17) Body System (01.00) 17. Raise the roof to the open position and lock into place. Ensure the two lock arms are located in their catches. 14. Raise the tension bow to 90°. Using the allen key provided in 15.
Page 102: Weather Seals
Convertible Roof (01.17) Body System (01.00) Weather Seals 20. Unlock the roof and lower to enable access to the trim strip. Tighten the remaining screws. Removal Installation Roof Pump WARNING DO NOT PLACE ANY OBJECTS ON THE TOP OF THE DEPLOYABLE ROLLBAR COVERS BEHIND THE REAR SEAT BACKS.
Page 103 Convertible Roof (01.17) Body System (01.00) 9. Remove the rear closing panel. 6. Disconnect two wiring harness plugs. 10. Disconnect the hydraulic pipes. Connect feed and return hydraulic pipes to create an hydraulic loop. 7. Manually raise the tension bow to 90°. Creating hydraulic loops will enable the hydraulic rams to For access to the hydraulic pipes and wiring harness plugs.
Page 104: Installation
Convertible Roof (01.17) Body System (01.00) 12. Withdraw the hydraulic pipes and the wiring harness cables through the vehicle body, while lowering the 4. Raise the pump and pump plate assembly into position pump. and secure. Torque bolts to 7-10 Nm. Installation Take care not to trap hydraulic pipes and wiring harness 1.
Page 105: Roof Module
Convertible Roof (01.17) Body System (01.00) Roof Module Installation 1. Raise the roof module into position and connect the two Removal wiring harness plugs. 1. Remove the ignition key and wait for a minimum of five 2. Install the roof module and plate assembly. Torque bolts seconds.
Page 106 Convertible Roof (01.17) Body System (01.00) Install the pump and pump plate unit. 4. Remove the roof lid support. 5. Connect the vehicle battery. Open the boot lid. 6. Connect the boot area wiring harness plug. 1-17-12 Workshop Manual Issue 3 October 2007...
Page 107: Bumpers (01.19)
Bumpers (01.19) Body System (01.00) Body System (01.00) Bumpers (01.19) Front Bumper Specifications 4. Remove bolts (x8 (x4 each side)) that secure the bumper. Torque Figures Description lb. / ft. Bumper to bumper bracket Maintenance Repair Operation Time (ROT) Item Code Bumper Remove / Install 01.19.AB...
Page 108: Installation
Bumpers (01.19) Body System (01.00) 5. Disconnect the retaining clips (x2). Use a tool, i.e. a long screwdriver, to unclip the bumper from the vehicle body. 6. Pull the bumper from the clips located in the front grill. Withdraw the bumper from the vehicle. Installation 1.
Page 109: Rear Bumper
Bumpers (01.19) Body System (01.00) Rear Bumper Specifications 2. Remove the bumper tag screw. Torque Figures Description lb. / ft. Bumper to bumper bracket 1.5-2.5 Maintenance Repair Operation Time (ROT) Item Code Bumper Remove / Install 01.19.BB Removal 1. Remove the light clusters. Open the boot and remove the trim from around the light cluster mounts.
Page 110 Bumpers (01.19) Body System (01.00) 3. Remove screws x4 (2 each side). 7. Remove screws (x4 (x2 each side)) from the bumper. 4. Remove bolt from inside the boot (1 each side). 8. Remove bolts (x4 (x2 each) that secure the exhaust 5.
Page 111: Installation
Bumpers (01.19) Body System (01.00) 9. Disconnect the retaining clips (x2). Use a tool, i.e. a long screwdriver, to unclip the bumper from the vehicle body. 10. Disconnect the two clips in the top centre of the bumper. Withdraw the bumper from the vehicle. Installation 1.
Page 112 Bumpers (01.19) Body System (01.00) 1-19-6 Workshop Manual Issue 3 October 2007...
Page 113: Restraining Devices (01.20)
Restraining Devices (01.20) Body System (01.00) Body System (01.00) Restraining Devices (01.20) Seat Belts This vehicle has four inertia reel safety belts installed. The The safety belt retractors, which are mounted within the inertia belt reels automatically tension the belts to provide base of the B pillars, incorporate a torsion bar load limiting security with comfort.
Page 114: Emergency Locking Retractor (Elr)
Restraining Devices (01.20) Body System (01.00) Emergency Locking Retractor (ELR) Torque Figures The retractors in all seat positions feature ELR. During any Description period of sudden deceleration, or under lateral load when 3 5 nm . cornering at speed, a sensor weight within the safety belt (2 6 lb / ft .) retractor moves a locking pawl against the teeth on the Re a r Se a t...
Page 115: Airbag System
Restraining Devices (01.20) Body System (01.00) Airbag System Driver airbag Module The airbag system is designed to provide increased collision protection for front seat occupants in addition to that The driver airbag module is installed in the steering wheel, provided by the safety belt system. Safety belt use is the cover forming the outer surface of the steering wheel necessary to obtain the best occupant protection and to boss.
Page 116: Restrains Control Module (Rcm)
Restraining Devices (01.20) Body System (01.00) Restrains Control Module (RCM) The primary purpose of the RCM is to discriminate between an event that warrants an airbag system deployment and an event that does not. The RCM governs the operation of the whole system and performs continual system diagnostics.
Page 117: Side Impact Airbag
Restraining Devices (01.20) Body System (01.00) Side Impact Airbag 3. Remove the airbag trim panel. Caution Removal Withdraw the airbag panel carefully. The airbag panel 1. Remove the earth (‘-ve’) terminal from the vehicle can crease if forced out. battery and ensure the ignition key is removed. Remove screws (x3).
Page 118: Deployable Rollbars
Restraining Devices (01.20) Body System (01.00) Deployable Rollbars WARNING DO NOT PLACE ANY OBJECTS ON THE TOP OF THE DEPLOYABLE ROLLBAR COVERS BEHIND THE REAR SEAT BACKS. WARNING DO NOT ALLOW ANY PERSON TO SIT ON THE DEPLOYABLE ROLLBAR COVERS AT ANY TIME. WARNING IF THE ROOF IS NOT STOWED AND THE DEPLOYABLE ROLLBARS DEPLOY THEY WILL BREAK...
Page 119 Restraining Devices (01.20) Body System (01.00) 4. Install the rear closing panel. WARNING The two center screws are installed when the 3rd center ENSURE THAT THE DEPLOYABLE ROLLBARS ARE console trim panel is installed. SECURED IN THE LOWERED POSITION. 9. Remove bolts x6 that secure the deployable rollbar unit. Withdraw the ROPS unit.
Page 120: Rollbar Sensor
Restraining Devices (01.20) Body System (01.00) Rollbar Sensor Remove 1. Disconnect the vehicle battery at the negative terminal and ensure the ignition key is removed. WARNING ALLOW A TWO MINUTE POWER DOWN PERIOD BEFORE PROCEEDING. THIS WILL ENSURE THAT THERE IS NO POWER TO THE DEPLOYABLE ROLLBAR SYSTEM.
Page 121: Frame And Mounting (02.00)
Frame and Mounting (02.00) Contents Subframes (02.01) ..........2-1-2 Specifications............1-2 Maintenance ............1-2 Front Subframe ............1-2 Removal.............. 1-2 Installation ............1-3 Rear Subframe ............1-4 Removal.............. 1-4 Installation ............1-8 Issue 3, October 2007 Workshop Manual 2-1-1...
Page 122: Subframes (02.03)
Subframes (02.01) Frame and Mounting (02.00) Frame and Mounting (02.00) Subframes (02.01) Specifications Torque Figures Description lb. / ft. Subframe to Front Structure 105-125 77.5-92.5 Subframe to Body 105-125 77.5-92.5 Engine Mounts Steering Rack Torque tube (rear) 43-57 32-42.5 Drive Plate (auto only) 60-85 45-63 Spring and Damper top mounting...
Page 123: Installation
Subframes (02.01) Frame and Mounting (02.00) 11. Remove bolts (x12) that secure the subframe to the 2 Torque the bolts that secure the subframe to the body and the front structure. body to 105-125 Nm. Withdraw the subframe. Bolts x2 (each side) 3 Torque the bolts that secure the subframe to the 01-02-14a front structure to 105-125 Nm.
Page 124: Rear Subframe
Subframes (02.01) Frame and Mounting (02.00) Rear Subframe 3. Install the steering rack bolts (x3). Torque bolts to 115 Nm. Repair Operation Time (ROT) Release the ‘Ty-wraps’ on the steering rack. Item Code Rear Subframe 02.01.CA Removal 1. Disconnect the vehicle battery. WARNING IF RASING VEHICLE ON A ‘TWO POST’...
Page 125 Subframes (02.01) Frame and Mounting (02.00) 6. Remove the silencer assembly. 9. Manual Transaxle Only. 7. Automatic Gearbox Only. Disconnect the wiring harness plug. Remove the gearbox coolant pipes. Remove the coolant thermostat from it’s mounting bracket. Disconnect the coolant pipes from the gearbox. Cap the pipes open ends.
Page 126 Subframes (02.01) Frame and Mounting (02.00) 11. Automatic Transaxle Only. 14. Disconnect the brake pipes. Remove the bolts (x3) that secure the torque tube drive plate to the torque converter. Caution 12. Disconnect the subframe wiring harness. Brake fluid must not be allowed to contact vehicle paint work.
Page 127 Subframes (02.01) Frame and Mounting (02.00) 17. Remove the subframe securing bolts. 18. Manual Transaxle only. Raise the vehicle to allow access to disconnect the gear The anti-roll bar must be removed before the two rear bolts can be completely removed. selector cables.
Page 128: Installation
Subframes (02.01) Frame and Mounting (02.00) 21. Automatic Gearbox Only. Install a torque converter transit bracket. 22. Retain the spacers from each rear subframe mounting pad. These should be installed in the same positions when the subframe is installed. 23. If required, remove the transaxle from the subframe (Refer to ’Transmission (07.00)’, page 7-1-1) Installation 1.
Page 129 Subframes (02.01) Frame and Mounting (02.00) 9. Install the spring and damper units. 13. Automatic Gearbox Only. Lower the vehicle to line up the spring and damper Install to the gearbox: mounts to the body. • Manual override cable Install bolts (x4) to each mount. Torque to 85 Nm. •...
Page 130 Subframes (02.01) Frame and Mounting (02.00) 2-1-10 Workshop Manual Issue 3, October 2007...
Page 131: Engine System (03.00)
Engine System (03.00) Contents Engine Assembly (03.00) ........3-1-3 Maintenance............4-3 Description ............. 1-3 Coolant Drain / Fill ..........4-3 Maintenance ............1-4 Pressure Tests ............4-3 Engine ..............1-4 Cooling System ........... 4-3 Removal.............. 1-4 Pressure Cap ............4-3 Installation ............1-11 Radiator..............
Page 132 Valve Train (03.09)..........3-10-1 Air Charging (03.12) ...........3-13-1 Description ............10-1 Description ............13-1 Camshafts ............10-1 Air Induction System ..........13-1 Specifications ............10-1 Specifications............13-1 Maintenance ............10-1 Maintenance ............13-2 Valve Timing Chains..........10-1 Air Filter...............13-2 Removal ............10-1 Removal ............13-2 Installation ............10-2 Installation ............13-2 LH Cylinder Head (Cylinders 7-12).....10-2 Air Filter Box ............13-3 RH Cylinder Head (Cylinders 1-6) ......10-3 Removal ............13-3...
Page 133: 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 6.0 litre 60° V12 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.
Page 134: Maintenance
Engine Assembly (03.00) Engine (03.00) Maintenance 6. Remove the washer bottle neck bracket. 7. Remove the ‘slam’ panel. Engine 8. Withdraw the plastic cover and disconnect the forward wiring harness plugs. Repair Operation Time (ROT) Item Code Engine Remove and Install 03.00.AA Including engine Remove from the frame Remove...
Page 135 Engine Assembly (03.00) Engine (03.00) 10. Disconnect the following from the forward cross 12. Remove the bolts and the reinforcement brackets from member. the inner wing. • The reinforcement struts Remove the header tank to gain access. There is a wiring harness plug connected to the header tank on the under side.
Page 136 Engine Assembly (03.00) Engine (03.00) 16. Lift the vehicle and make it safe. 24. Remove the engine bay fusebox and bracket. Remove the screws that attach the rear section of the road wheel arch liner. Hold back the rear section of the road wheel arch liner to allow the foot of the vehicle lift to be positioned correctly.
Page 137 Engine Assembly (03.00) Engine (03.00) 26. Remove the PCMs. Disconnect the engine wiring 30. Disconnect the front brake pipes: harness plugs and remove the three screws that secure Caution the PCM (each side). Do not let brake fluid touch the vehicle paint work. 27.
Page 138: Removal
Engine Assembly (03.00) Engine (03.00) 32. Disconnect the fuel lines. 37. Disconnect the handbrake cable from the rear subframe (Refer to ’Hand Brake (06.05)’, page 6-5-1). Use the brake cable release tool (Refer to ’206-103 (Handbrake Cable Removal)’, page 20-1-4). 33.
Page 139 Engine Assembly (03.00) Engine (03.00) 40. Remove the rear brake pipe brackets. 43. Put scribe marks to show the relation of the front subframe and front structure to the vehicle body for accurate Install. 44. Remove the bolts (x12) that attach the front subframe and front structure to the body.
Page 140 Engine Assembly (03.00) Engine (03.00) 47. Remove the bolts that attach the rear subframe. 48. Manual Transaxle only. Lift the vehicle to get access to disconnect the gear You must remove the anti-roll bar before the two rear bolts can be fully removed. selector cables.
Page 141 Engine Assembly (03.00) Engine (03.00) Install 8. Torque-tighten the front subframe and front structure bolts: 1. Lower the vehicle on to the powertrain assembly. Align the marks on the front subframe and front structure Make sure that all pipes and cables are not caught as to the body.
Page 142 Engine Assembly (03.00) Engine (03.00) 11. Automatic Gearbox Only. 25. Connect the earth points to the bulkhead. Install the manual override cable. • Right side 12. Manual Gearbox Only. • Install the gear change linkage • Install the wiring harness plugs 13.
Page 143 Engine Assembly (03.00) Engine (03.00) 41. Charge the A/C unit (Refer to ’Air Conditioning (A/C) 7. Attach the lifting eyes (x4) to the cylinder heads. System (12.03)’, page 12-3-1). 8. Attach the engine lifting gear to an applicable hoist. 42. Check the road wheel alignment (Refer to ’Road Wheel 9.
Page 144 Engine Assembly (03.00) Engine (03.00) Install 1. Install the engine lifting gear to an applicable hoist. 2. Raise and move the engine to the frame. 3. Make sure that the torque tube is adequately supported and move the engine to the torque tube. 4.
Page 145: Engine Structure (03.01)
Engine Structure (03.01) Engine (03.00) Engine (03.00) Engine Structure (03.01) Description Engine Block Dowels are installed to the principal mating faces of the block to ensure accurate alignment of cylinder heads, front timing cover, auxiliaries, etc. The 60° V12 aluminium engine block incorporates paths for water cooling, oil distribution and positive crankcase ventilation.
Page 146: Inlet / Exhaust Manifolds
Engine Structure (03.01) Engine (03.00) Cylinder Heads Each cylinder has two inlet and two exhaust valves. The valves are operated by cam followers below each camshaft. Valve clearances are kept at zero by a hydraulic tappet system (lash adjuster) that is pressurised from the main engine lubrication system.
Page 147: Maintenance
Engine Structure (03.01) Engine (03.00) Maintenance 11. Remove the camshaft followers and lash adjusters. Keep them in the sequence that they are removed. Cylinder Head Remove 1. Remove the engine from vehicle (Refer to ’Engine’, page 3-0-4) 2. Remove the inlet manifold (Refer to ’Inlet Manifold’, page 3-1-7).
Page 148 Engine Structure (03.01) Engine (03.00) 12. Remove the two M8 bolts and the 14 M10 bolts from 13. Remove the cylinder head. Discard the cylinder head the cylinder head in the sequence shown in the figure gasket. below. Cover the engine block to prevent contamination. L eft S ide S hown E ngine F ront...
Page 149 Engine Structure (03.01) Engine (03.00) Release Caution 1 Loosen the M10 bolts 1-14 a minimum of one full Do the following “Torque - Release - Torque” sequence turn (360 degrees). exactly as specified, to make sure that the cylinder head seals to the engine block correctly.
Page 150 Engine Structure (03.01) Engine (03.00) 9. Put the camshafts in position with the timing marks in 13. Do the steps that follow to torque-tighten the camshaft the positions shown in the figure below. attachment bolts:- 13.1 Gradually tighten all of the bolts in the sequence In the positions shown, the camshafts will be at their lowest in the journals.
Page 151 Engine Structure (03.01) Engine (03.00) 16. Install the timing cover (Refer to ’Timing Cover’, page 3- 10-3). 17. Install the accessory drive belt (Refer to ’Drive Belt’, page 3-5-1) 18. Install the camshaft cover (Refer to ’Camshaft Cover’, page 3-10-1). 19.
Page 152 Engine Structure (03.01) Engine (03.00) 5. Remove the items that follow from the inlet manifold:- 6. Remove the thermostat housing by-pass hose. Seal the open ends. 3-1-8 Workshop Manual Issue 3 October 2007...
Page 153 Engine Structure (03.01) Engine (03.00) 7. Remove the connectors that follow: 9. Disconnect the fuel rails from the fuel supply hoses. • The harness plug for the temperature sender wiring on The hose unions on the fuel supply for the left and right fuel the fuel rail rails are different sizes.
Page 154 Engine Structure (03.01) Engine (03.00) Install 3. Install new O-rings on the injectors. Note position of O-rings Make sure that all mating faces are clean and there is no • Blue (top) damage or contamination. • Green (bottom) 1. Install a new inlet manifold gasket to the inlet manifold. Engage the two ‘lipped’...
Page 155 Engine Structure (03.01) Engine (03.00) Exhaust Manifold 2. Remove the starter motor. Repair Operation Time (ROT) Item Code Exhaust Manifold Renew 09.03.DB 09.03.EB Remove 1. Disconnect the vehicle battery. 2. Raise the vehicle and make safe. 3. Remove the front roadwheels and the wheel arch liners. 4.
Page 156 Engine Structure (03.01) Engine (03.00) 6. Remove the exhaust manifold:- 2. Remove the exhaust heat shields. Remove the manifold nuts (x12). 3. Remove the dip stick. Remove the nuts and bolts (x3) (refer to the figure below). 4. Disconnect the heated oxygen sensors (x2) and the catalyst monitor sensors (x2).
Page 157 Engine Structure (03.01) Engine (03.00) Install 5. Remove the exhaust manifold:- Remove the manifold nuts (x12). Use new gaskets. 1. Put a new gasket and the exhaust manifold in position on the cylinder head. 2. Install the nuts (x12) that attach the exhaust manifold. 3.
Page 158 Engine Structure (03.01) Engine (03.00) 3-1-14 Workshop Manual Issue 3 October 2007...
Page 159: Lubrication System (03.02)
Lubrication System (03.02) Engine (03.00) Engine (03.00) Lubrication System (03.02) Description The engine has a wet-sump lubrication system. The oil pump is driven by the crankshaft. The oil pump gets oil from the sump and pumps it through a pick-up tube to an oil strainer.
Page 160: Engine Oil Specification
1. Remove the front undertray. Engine Oil Specification 2. Remove the oil filter. An oil of 0W-30 viscosity that is equal to Aston Martin specification WSS M2C913-A/B or 0W-40 viscosity that is equal toAston Martin specification WSS-M2C937-A is recommended. Where this is not possible, oil that is equal to the following standards can be used.
Page 161 Lubrication System (03.02) Engine (03.00) Install LH Drive. 1. Remove the front undertray. 1. Apply a thin layer of clean engine oil to the lip of the oil 2. Remove the air intake from the throttle body. filter. 3. Remove the throttle body. 2.
Page 162 Lubrication System (03.02) Engine (03.00) 6. Remove the bolts (x15 M8) and (x5 M6) that attach the sump. Remove the sump. 7. Discard the sump gasket and the oil seal for the oil pump. 4. Apply dots (10 mm Dia approximately) of sealant to the sump sealing surface in the positions shown in the figure below.
Page 163 Lubrication System (03.02) Engine (03.00) 5. Install the sump. 6. Install the coolant pipe. 7. Install the front subframe (Refer to ’Front Subframe’, Make sure that the oil outlet seal for the sump correctly engages with the oil pump inlet before you put the sump in page 2-1-2).
Page 164 Lubrication System (03.02) Engine (03.00) Oil Pump 3. Install the timing cover (Refer to ’Timing Cover’, page 3- 10-3). Repair Operation Time (ROT) 4. Install the sump (Refer to ’Sump’, page 3-2-3) with a Item Code new gasket and a new oil seal for the oil pump. Oil Pump Renew Make sure that the oil outlet seal for the sump correctly engages with the oil pump inlet before you put the sump in...
Page 165: Cooling System (03.03)
Cooling System (03.03) Engine (03.00) Engine (03.00) Cooling System (03.03) Description Water pump Radiator Coolant Reservoir Cooling fan motor control module Thermostat Pressure cap Electric cooling fans (x2) Engine oil cooler Coolant Circuit Issue 4, November 2008 Workshop Manual 3-3-1...
Page 166: Water Pump
Cooling System (03.03) Engine (03.00) Water Pump In-Vehicle Heating The water pump is of a standard design and it is installed at A hose from the front of the thermostat housing directs the front of the engine. It is driven by the accessory drive coolant to the heater water valve which remains closed belt.
Page 167: Maintenance
Cooling System (03.03) Engine (03.00) Maintenance 5. Fill the cooling system with the specified coolant to the maximum level mark in the coolant reservoir. Caution 6. Install the pressure cap. ‘Spring-Band’ Clips WARNING Install‘Spring-band’ clips As shown below: DO NOT REMOVE THE PRESSURE CAP WHEN THE COOLANT IS HOT.
Page 168: Radiator
Cooling System (03.03) Engine (03.00) Radiator - Remove and Install Disconnect the wiring harness plug from the crash sensors (x2). Repair Operation Time (ROT) Remove wiring harness locators (x2). Item Code Radiator - Remove and Install 03.03.EB Remove 1. Drain the engine coolant. 2.
Page 169 Cooling System (03.03) Engine (03.00) 3. Remove the bolt (x1) that attaches thermostat housing support bracket from the timing cover. 4. Remove the bolts (x3) to release the thermostat housing. 8. Remove the hoses (shown in figure below) from the radiator.
Page 170 Cooling System (03.03) Engine (03.00) 3. Attach the water pump pulley to the water pump with the bolts (x4). Torque bolts (x4) to 23-27 Nm. 4. Install the accessory drive belt (Refer to ’Drive Belt’, page 3-5-1). 5. Fill the cooling system. 3.
Page 171: Fuel Charging System (03.04)
Fuel Charging System (03.04) Engine (03.00) Engine (03.00) Fuel Charging System (03.04) Description The fuel system is an electronic return-less that has the advantages that follow: there is less fuel tank vapour, it needs less electrical power and it does not need a fuel return line. Fuel is supplied at high-pressure to the injectors through two fuel rails (primary and secondary).
Page 172: Maintenance
Fuel Charging System (03.04) Engine (03.00) Maintenance 4. Disconnect the wiring harness plugs that follow: • Temperature sender plugs Depressurising the Fuel System • Pressure sensor plugs Repair Operation Time (ROT) • Injector harness plugs Item Code 5. Remove the bolts (x3) that attach the fuel rail to the inlet Fuel System Depressurising 10.01.EK manifold.
Page 173 Fuel Charging System (03.04) Engine (03.00) Injectors Repair Operation Time (ROT) Item Code Fuel Injectors 03.04.GB 03.04.FB Remove 1. Remove the fuel rails. 2. Remove the injectors. Discard the O-rings. Install 1. Install the injectors, complete with new O-rings. Put the O-rings in the positions that follow: Blue at the top, Green green at the bottom.
Page 174 Fuel Charging System (03.04) Engine (03.00) 3-4-4 Workshop Manual Issue 3 October 2007...
Page 175: Accessory Drive System (03.05)
Accessory Drive System (03.05) Engine (03.00) Engine (03.00) Accessory Drive System (03.05) Maintenance Drive Belt Description Repair Operation Time (ROT) Item Code Drive Belt Renew 03.05.AB Remove 1. Remove the undertray. 2. Use a 3/8 in. ratchet handle 'T'-bar to rotate the drive belt tensioner clockwise and remove the drive belt from the idler pulley.
Page 176 Accessory Drive System (03.05) Engine (03.00) 3-5-2 Workshop Manual Issue 3 October 2007...
Page 177: Engine Cranking System (03.06)
Engine Cranking System (03.06) Engine (03.00) Engine (03.00) Engine Cranking System (03.06) Maintenance Starter Motor Starting System The starting system has the parts that follow: Repair Operation Time (ROT) • A pre-engaged type starter motor Item Code • A battery Starter motor Renew 03.06.AB Remove...
Page 178 Engine Cranking System (03.06) Engine (03.00) 8. Remove bolts (x2) that secure the starter motor. 9. Remove the starter motor and the bracket for the oxygen gas sensors. Install 1. Put the starter motor and the bracket for the oxygen gas sensors in position on the bell housing.
Page 179: Ignition System (03.07)
Ignition System (03.07) Engine (03.00) Engine (03.00) Ignition System (03.07) Description There is an ignition coil attached to each spark-plug. Each cylinder has one spark-plug and ignition coil assembly. There are two crankshaft sensors installed on the front of the engine - only the right sensor is used. The second crankshaft sensor is installed on the left side of the flywheel housing.
Page 180: Maintenance
Ignition System (03.07) Engine (03.00) Maintenance Install 1. Install the spark plugs. Torque to 16-20 Nm. Spark Plugs 2. Install the ignition coils. Torque the bolts to 5-7 Nm. Repair Operation Time (ROT) 3. Connect the wiring harness plugs to ignition coils. Item Code 4.
Page 181: Emission Control (03.08)
Emission Control (03.08) Engine (03.00) Engine (03.00) Emission Control (03.08) System Description To prevent pollution, the crankcase gases (blow-by) go into the engine intake system. All poisonous fumes will be burned when the engine operates. There is a part-load (1) and a full-load (2) breather system that vents the engine correctly during all conditions of operation. The crankcase gases are released through channels in the walls of the cylinder block.
Page 182 Emission Control (03.08) Engine (03.00) 3-8-2 Workshop Manual Issue 3 October 2007...
Page 183: Valve Train (03.09)
Valve Train (03.09) Engine (03.00) Engine (03.00) Valve Train (03.09) Maintenance Valve Timing Chains Description Camshafts Repair Operation Time (ROT) Item Code The Inlet and exhaust camshafts in each cylinder head are chain-driven by the crankshaft. Timing Chain Renew LH RHD 0309AA Timing Chain Renew RH RHD 0309AB...
Page 184 Valve Train (03.09) Engine (03.00) Left Cylinder Head (Cylinders 7-12) Remove the fixed timing chain guide (bolts x2). Repeat steps 6.1 to 6.3 for the second timing chain 2. Engage the camshaft timing service tool (Refer to ’303- tensioner and timing chain guides. 713 (Camshaft Set)’, page 20-1-5) to the flats on the 7.
Page 185 Valve Train (03.09) Engine (03.00) Right Cylinder Head (Cylinders 1-6) 10. Install the timing chain with the marked links (x3) aligned with the marks on the crankshaft and the 7. Make sure that the crankshaft key is in the vertical camshaft sprockets.
Page 186 Valve Train (03.09) Engine (03.00) Valve Timing Check 6. Remove the camshaft cover (Refer to ’Camshaft Cover’, page 3-10-1). 1. Rotate the crankshaft counter-clockwise at least 60°, 7. Remove the timing cover (Refer to ’Timing Cover’, page then rotate clockwise to TDC for No. 1 cylinder (with 3-10-3).
Page 187 Valve Train (03.09) Engine (03.00) 15° 15° 13. Put a cover on the engine block to prevent contamination. 15° 15° Install Make sure that all mating surfaces are clean and smooth. 1. Install all of the lash adjusters. Soak the lash adjusters in engine oil. Operate the adjusters to fill them with oil.
Page 188 Valve Train (03.09) Engine (03.00) 9. Do the steps that follow to torque-tighten the camshaft 12. Install the timing cover (Refer to ’Timing Cover’, page 3- attachment bolts:- 10-3). Gradually tighten all of the bolts in the sequence 13. Install the accessory drive belt (Refer to ’Drive Belt’, shown.
Page 189: Engine Sealing (03.10)
Engine Sealing (03.10) Engine (03.00) Engine (03.00) Engine Sealing (03.10) 3. Remove the spark plug cover. Specifications Torque Figures Description lb. / ft. Camshaft cover 8-12 Timing cover 23-27 17-18.5 Idler pulley 25-27 18.5-20 Sump bolts 11.5 90° Crankshaft damper Back out a minimum of 360°...
Page 190 Engine Sealing (03.10) Engine (03.00) 7. Remove the bolts (x15) that attach the camshaft cover. 3. Install the camshaft cover. Torque the bolts (x15) to 8-12 Nm. in the sequence shown below. Remove the camshaft cover. Discard all of the seals from the camshaft cover. E ngine 8.
Page 191 Engine Sealing (03.10) Engine (03.00) Timing Cover 6. Remove the bolts (x2) that attach the water pump to the timing cover. Remove the pump. Repair Operation Time (ROT) Item Code Timing Chain Cover 0310AF Remove 1. Drain the engine oil. 2.
Page 192 Engine Sealing (03.10) Engine (03.00) Install 11. Remove the thermostat housing: 11.1 Remove the hoses (x4). 1. Make sure that the mating surfaces of the timing cover 11.2 Remove the bolts (x3). and the crankcase are clean and smooth. Install new timing cover seals.
Page 193 Engine Sealing (03.10) Engine (03.00) 4. Install the thermostat housing with the thermostat and a Make sure that the crankshaft does not turn (use tool new O-ring (Refer to ’Thermostat - Remove and Install’, 303-1360) and torque the crankshaft damper bolt in page 3-3-5).
Page 194 Engine Sealing (03.10) Engine (03.00) Crankshaft Rear Oil Seal 3. Install the oil seal slinger (Refer to ’303-1174 (Crankshaft Rear Oil Seal Slinger Install)’, page 20-1-4). Repair Operation Time (ROT) The oil seal slinger only installs one way on the oil seal Item Code slinger install tool.
Page 195 Engine Sealing (03.10) Engine (03.00) Crankshaft Front Oil Seal Repair Operation Time (ROT) Item Code Crankshafts Front Oil Seal Remove 1. Remove the timing cover (Refer to ’Camshaft Cover’, page 3-10-3). 2. Remove the oil seal from the timing cover. Install 1.
Page 196 Engine Sealing (03.10) Engine (03.00) 3-10-8 Workshop Manual Issue 3 October 2007...
Page 197: Power Conversion (03.11)
Power Conversion (03.11) Engine (03.00) Engine (03.00) Power Conversion (03.11) Specifications Description Crankshaft Crankshaft Main-bearing diameter 67.480 - 67.504 Main-bearing clearance 0.025 - 0.050 The crankshaft is installed in 7 main-bearings. The end loads Refer to the main-bearing grade chart for bearing shell are absorbed by thrust washers that are installed at the selection.
Page 198 Power Conversion (03.11) Engine (03.00) Main-Bearing Grade Chart Torque Figures Description lb./ft. The finished diameter of the crankshaft main-bearing bores Engine block spread 18.5 is shown by letters stamped on the cylinder block face. The tool first letter, for example ‘D’, refers to the No.1 journal. The Main-bearings 1.
Page 199 Power Conversion (03.11) Engine (03.00) Minimum Block Diameter G H I M N O P 72.400 .401 .402 .403 .404 .405 .406 .407 .408 .409 .410 .411 .412 .413 .414 .415 .416 .417 .418 .419 .420 .421 .422 .423 .424 67.504 67.503 67.502...
Page 200 Power Conversion (03.11) Engine (03.00) 5. Remove the bolts (x6) that attach the rear oil seal 7. Remove the piston and the connecting-rod assemblies: retainer and withdraw the seal retainer and oil seal. Remove the connecting-rod bolts to release the connecting-rod caps and the bearings.
Page 201 Power Conversion (03.11) Engine (03.00) Examine the Components 8. Remove the main-bearing caps and the bearing shells. To remove the bearing caps, spread the engine block side 1. Examine the crankshaft journals for wear, scuffing or walls using the engine block spreading tool (Refer to ’303- other defects.
Page 202 Power Conversion (03.11) Engine (03.00) 3. Install the main-bearings and caps. Caution Apply oil below the heads of the main-bearing bolts. Do not get oil on the threads. Loosely install them into their holes with your hand. Install the stud bolts for No. 3 and 6 main-bearing caps in the positions you recorded during Remove.
Page 203 Power Conversion (03.11) Engine (03.00) 6. Install the side bolts for the main caps . Torque the side 8. Do a check the torque required to turn the crankshaft. bolts for the main caps, in the sequence shown in the The torque must not be more than 6 Nm.
Page 204 Power Conversion (03.11) Engine (03.00) 13. Install the sump. Caution Make sure that the sump oil outlet goes into to the oil pump Make sure that the crankshaft key is in the vertical inlet before the sump is installed up to the engine block. position.
Page 205 Power Conversion (03.11) Engine (03.00) Flywheel 1. Heat the piston to approximately 70°C and install the connecting-rod and piston pin. Repair Operation Time (ROT) WARNING Item Code PISTONS ARE HEATED TO APPROX. 70°C. WEAR Clutch and Flywheel Renew 08.00.HA PROTECTIVE CLOTHING, E.G. GLOVES, TO AVOID BURNS.
Page 206 Power Conversion (03.11) Engine (03.00) Install 8. Put a support under the flywheel. 9. Remove the flywheel attachment bolts. 1. Put an applicable support under the flywheel. Install the Install flywheel bolts (x2) into the threaded ‘jacking’ flywheel on to the crankshaft and align the attachment holes in the flywheel.
Page 207: Air Charging (03.12)
Air Charging (03.12) Engine (03.00) Engine (03.00) Air Charging (03.12) Description Air Induction System The intake air is filtered and then goes through two mass air flow (MAF) meters. The signals from the MAF meters are supplied to the PCMs and are used with other signals to calculate the correct amount of fuel. The correct air/fuel ratio is approximately 14.3 parts of air to 1.0 part fuel, by weight.
Page 208 Air Charging (03.12) Engine (03.00) Maintenance 21. Remove the air filter. Air Filter Repair Operation Time (ROT) Item Code Air Filter Renew 03.12.CB 03.12.DB Remove If you use a two-post vehicle lift, remove the screws that attach the rear part of the road wheel arch liner. Hold back the rear part of the road wheel arch liner to let you put the foot of the vehicle lift in the correct position.
Page 209 Air Charging (03.12) Engine (03.00) Air Filter Box Repair Operation Time (ROT) Item Code Air Box Renew 03.12.AB 03.12.BB Remove If you use a two-post vehicle lift, remove the screws that attach the rear part of the road wheel arch liner. Hold back the rear part of the road wheel arch liner to let you put the foot of the vehicle lift in the correct position.
Page 210 Air Charging (03.12) Engine (03.00) 3-12-4 Workshop Manual Issue 3 October 2007...
Page 211: Evaporative Emissions (03.13)
Evaporative Emissions (03.13) Engine (03.00) Engine (03.00) Evaporative Emissions (03.13) System Operation When the fuel fumes are forced from the fuel tank, they go Description through a fill level vent-valve (3) (that is normally open) and The evaporative loss system prevents the release of fuel the roll-over valves (2).
Page 212 Evaporative Emissions (03.13) Engine (03.00) 3-13-2 Workshop Manual Issue 3 October 2007...
Page 213: Engine Management System (03.14)
Engine Management System (03.14) Engine (03.00) Engine (03.00) Engine Management System (03.14) The electronic engine control system has two Powertrain The system gives the necessary engine control to: Control Modules (PCMs) and a number of sensors and • Keep the the exhaust emissions and the fuel consumption devices that do operations.
Page 214 Engine Management System (03.14) Engine (03.00) Specifications T - Transmission C0634- Description I / 0 Circuit Page Powertrain Control Modules (PCMs) Park TT Secondary (B) Primary (A) HTR 12 HTR 22 CNVNT C - Cowl C0635- Description I / 0 Circuit Page Start enable ISO-K LH and RH Drive...
Page 215 Engine Management System (03.14) Engine (03.00) PCM B C - Cowl C0635- Description I / 0 Circuit Page View when you look into the connectors on the PCM Power ground Caution Power ground Do a check to make sure the connectors are correct. Power ground IGNSNS E - Engine...
Page 216 Engine Management System (03.14) Engine (03.00) Maintenance T - Transmission C0637- Description I / 0 Circuit Page WDS Connection Engine coolant level The port for WDS connection is located in the drivers side PRI / Sec switch footwell on the transmission tunnel. MAF + MAF - CB 2 +...
Page 217 Engine Management System (03.14) Engine (03.00) Remove 11. Disconnect the three electrical connectors and remove the module. 1. Raise the vehicle and make it safe. 2. On Roadster vehicles, remove the centre undertray. 3. Remove the left side front wheel. 4.
Page 218 Engine Management System (03.14) Engine (03.00) 8. Disconnect the electrical connector from the side 3. Put the bracket in position and attach it with the three repeater. M6 screws. 4. Attach the harness to the bracket with the clips. 5. Attach the side repeater harness to the bracket with the four clips.
Page 219: Throttle Control (03.16)
Throttle Control (03.16) Engine (03.00) Engine (03.00) Throttle Control (03.16) Specifications Description Torque Figures Motorised Throttles Description lb./ft. Throttle body 8-12 There are two motorised throttles (1), one installed on each Maintenance inlet manifold. They accurately control the flow of air into the engine.
Page 220 Throttle Control (03.16) Engine (03.00) Install 1. Put the throttle body in position with a new O-ring. 2. Install the four bolts (1) and torque to 8-12 Nm. 3. Install the air intake pipe (1) and the electrical connector (2). 3-16-2 Workshop Manual Issue 3 October 2007...
Page 221 Suspension (04.00) Contents Road Wheel Alignment (04.00) ......4-1-2 Shock Absorber System (04.03)......4-4-1 Specifications ............1-2 Description............. 4-1 Maintenance ............1-2 Specifications ............4-1 Caster Angle ............1-3 Maintenance (Front)..........4-1 Adjustment (Front) ..........1-3 Spring and Damper Assembly ........ 4-1 Camber Angle............
Page 222: Suspension (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 Toe (in) 2.5’ (±2’) 10’ (+5’ / -0’) Refer to the geometry setup tool manufacture operating Total Toe 5’...
Page 223: Camber Angle
Road Wheel Alignment (04.00) Suspension (04.00) Caster Angle Adjustment (Front) Adjustment (Front) Check and if required adjust the camber angle. If the camber Ensure that the vehicle is at normal ride height. angle is correct but the caster angle is still incorrect, suspect Check tyre pressures.
Page 224 Road Wheel Alignment (04.00) Suspension (04.00) 4-0-4 Workshop Manual Issue 3 October 2007...
Page 225: 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 226: Symptoms
Front Suspension (04.01) Suspension (04.00) Symptoms Symptom Possible Cause Action Crabbing Front or rear suspension components / Inspect front and rear suspension systems. road wheel alignment Check / adjust road wheel alignment Drive axle damaged New drive axle. Front ‘Bottoming’ Spring(s) Check ride height.
Page 227: 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 228: Ball Joints
Front Suspension (04.01) Suspension (04.00) Ball Joints Removal 1. Raise the vehicle and make safe. Inspection 2. For each affected wheel station remove the road 1. Raise and support the vehicle. wheel(s). Prior to carrying out any inspection of the ball joints, inspect 3.
Page 229 Front Suspension (04.01) Suspension (04.00) 6. Using service tool (Refer to ’204-523 (Ball Joint Splitter)’, 8. If required, remove the hub from the vertical link. page 20-1-3), remove the track rod-end. Remove bolts (x4). Caution Do not use a hammer, etc., to ‘shock’ the track rod-end. Take care not to damage the ball joint boot.
Page 230: Installation
Front Suspension (04.01) Suspension (04.00) 9. Remove the spring and damper assembly. 11.Remove bolts (x2) that secure the lower suspension arm to the subframe. Withdraw the lower suspension arm. Caution Ensure the damper is fully extended. If removing both spring and damper units - the engine bay cross brace will be released.
Page 231 Front Suspension (04.01) Suspension (04.00) 3. Install the bearing assembly to the vertical link (if 4. Install the anti-roll bar link assembly to the lower arm. removed). Torque to 110 Nm. Install the brake dust shield. Torque bolts (x3) to 9 Ensure that the washer installs as shown below.
Page 232: Anti-Roll Bar
Front Suspension (04.01) Suspension (04.00) Installation 12.Torque the suspension fixings with the vehicle at normal ride height (Refer to ’Specifications’, page 4-1-1): 1. Place the anti-roll bar in position and install the stabiliser • Lower suspension arm to the mountings. subframe (rear bush) - 185 Nm.
Page 233: Vertical Link
Front Suspension (04.01) Suspension (04.00) Vertical Link 7. Disconnect the upper suspension arm from the vertical link. Repair Operation Time (ROT) Item Code Vertical link Renew (LH) 04.01.GB (RH) 04.01.HB Removal 1. Raise the vehicle and make safe. 2. For each affected wheel station remove the road wheel(s).
Page 234 Front Suspension (04.01) Suspension (04.00) 4-1-10 Workshop Manual Issue 3 October 2007...
Page 235: 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 236 Rear Suspension (04.02) Suspension (04.00) Specifications Maintenance For details on: Torque Figures • Alignment (Refer to ’Road Wheel Alignment Description lb. / ft. (04.00)’, page 4-0-2) Brake Dust Shield. • Inspections (Refer to ’Suspension (04.00)’, page Bearing Assembly to the Vertical 4-1-1) link.
Page 237 Rear Suspension (04.02) Suspension (04.00) 6. Remove the anti-roll bar drop links. 7. Disconnect the vehicle height sensor (LH side). 4. Remove the halfshaft nut. 8. Remove the bolt that secures the track-rod arm to the 5. Disconnect the ABS sensor wiring harness plug. vertical link.
Page 238 Rear Suspension (04.02) Suspension (04.00) 12.If required, remove the bearing assembly from the 14.Remove the upper suspension arm. vertical link. 12.1 Remove bolts (x4) that secure the bearing assembly to the vertical link. 12.2 Press the bearing assembly from the vertical link. 15.
Page 239 Rear Suspension (04.02) Suspension (04.00) 4. Install the bearing assembly (if removed). • Bearing bolts to 50 Nm. • Dust shield bolts to 9 Nm. 9. Install the service brake and the handbrake calipers. Torque bolts to: • Service brake caliper to 20 Nm. + 66°-70° •...
Page 240 Rear Suspension (04.02) Suspension (04.00) Anti-roll Bar Caution Final tightening of the suspension components must be Repair Operation Time (ROT) carried out with the suspension arms at normal ride Item Code height. Failure to do this will over stress the suspension bushes when the suspension is deflected to max.
Page 241 Rear Suspension (04.02) Suspension (04.00) • Anti-roll bar link nuts to 110 Nm. Ensure that the washer installs between the stud and the suspension arm. 2. Install the rear undertray. 5. Disconnect the ABS sensor wiring harness plug. Vertical link Repair Operation Time (ROT) Item Code...
Page 242 Rear Suspension (04.02) Suspension (04.00) 7. Disconnect the upper suspension arm. 7. Install the halfshaft nut. Torque to 300 Nm. 8. Install the service brake and the handbrake calipers 8. Press the halfshaft from the vertical link. (Refer to ’Brake Caliper (Front and Rear)’, page 6-3-2). 9.
Page 243: Shock Absorber System (04.03)
Shock Absorber System (04.03) Suspension (04.00) Suspension (04.00) Shock Absorber System (04.03) 4. Remove the upper suspension arm from the body structure. Description Allow the upper suspension arm and the Vertical link to fall back, giving access to the spring and damper assembly. Movement of each road spring is independently damped by a telescopic, hydraulically-controlled shock absorber.
Page 244 Shock Absorber System (04.03) Suspension (04.00) 5. Torque the suspension fixings with the vehicle at normal ride height: • Upper suspension arm to the front structure - 115 Nm. • Spring and damper bolts to (top) 22.5 Nm. (bottom) 175 Nm. The engine bay cross brace must be torqued with the weight of the vehicle on the roadwheels.
Page 245: Removal
Shock Absorber System (04.03) Suspension (04.00) Maintenance (Rear) 6. Remove the vertical link lower bolt. Spring and Damper Assembly Repair Operation Time (ROT) Item Code Spring and Damper Unit Renew (LH) 04.03.CB (RH) 04.03.DB Removal 1. Raise the vehicle and make safe. 2.
Page 246 Shock Absorber System (04.03) Suspension (04.00) 2. Install the spring and damper assembly to the lower suspension arm. Torque bolt to 175 Nm. 3. Install the vertical link to the lower suspension arm. Torque to 175 Nm. 4. Install the track-rod arm. Torque to 115 Nm. 5.
Page 247: Road Wheels And Tyres (04.04)
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 speed performance of this vehicle. Only tyres of identical SAME VEHICLE SUCH AS RADIAL, BIAS OR BIAS specification may be installed as replacements.
Page 248: Usa Tyre Gradings
Road Wheels and Tyres (04.04) Suspension (04.00) USA Tyre Gradings Maintenance The following information relates to the tyre grading system Factory installed tyres and road wheels are designed to developed by the National Highway Traffic Safety operate satisfactory when inflated to the recommended Administration which grades tyres by tread wear, traction inflation pressures (Refer to ’Inspection and Verification’, and temperature performance.
Page 249: Tyre Replacement And Wheel Interchanging
• Only Aston Martin snow chains should be used become embedded in the tread. More frequent inspections • Snow chains must not be used on roads which are clear of...
Page 250: Road Test
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 251: Symptoms
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 252: 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 253: Misalignment Effects
Road Wheels and Tyres (04.04) Suspension (04.00) Misalignment Effects situation which tends to steer the road wheel to the right and left alternately. Misalignment Effect Dynamic imbalance of the tyre and road wheel assemblies Road wheels are correctly aligned All tyres will wear can be measured on suitable tyre balancing equipment, and but crabbing due to road camber equally.
Page 254: 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 Control module Tyre LED constant red. REPLACE DRIVER AWARENESS OF TYRE Fault Tyre pressure below specification.
Page 255: 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 ‘Smartyre’...
Page 256 Road Wheels and Tyres (04.04) Suspension (04.00) Tyre Rotation 4. Press ‘Tyre’ to increase or ‘Mode’ to decrease current value. WARNING 5. Press ‘Set’ to enter the new value into memory. THE ROAD WHEELS AND TYRES ARE ASYMMETRICAL AND DIFFERENT SIZES FRONT AND REAR. THEY Pressure Deviation Alert MUST NOT BE ROTATED FRONT TO REAR.
Page 257: Level 2 Programming
1. Press ‘Set’ for 5 seconds to enter level 2 programming. Low Pressure Alert 2. Press ‘Tyre’ until the desired vehicle axle is displayed. 3. Press ‘Mode’ to display the current SLOPE entry (DB9 is set at?) 4. If required, use ‘Tyre’ to increase or ‘Mode’ to decrease current value.
Page 258 Road Wheels and Tyres (04.04) Suspension (04.00) 4-4-12 Workshop Manual Issue 3 October 2007...
Page 259: Driveline (05.00)
Driveline (05.00) Contents Driveshaft (05.01)..........5-1-2 Description ............. 1-2 Specifications............1-2 Maintenance ............1-2 Torque Tube............1-2 Remove............... 1-2 Installation ............1-5 Halfshafts (05.05) ..........5-2-1 Specifications............2-1 Maintenance ............2-1 Halfshaft ..............2-1 Removal.............. 2-1 Installation ............2-1 Issue 3 October 2007 Workshop Manual 5-1-1...
Page 260: 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 the propshaft, transferring drive from the power unit to the gearbox. Engine power is transmitted to the rear wheels via a carbon fibre prop shaft. To prevent any shunting of the engine under high acceleration, the engine and transaxle are connected with an aluminium torque tube which surrounds the prop shaft.
Page 261 Driveshaft (05.01) Driveline (05.00) 5. Remove the heat shields. 12. Automatic Gearbox Only. Remove the transmission oil coolant pipes from the torque tube. Heatshield Remove Front Nut 01 05 019 Rear of Heatshield 13. Automatic Gearbox Only. Remove the drive plate. Remove Bolts 01-05-020 14.
Page 262 Driveshaft (05.01) Driveline (05.00) 15. Manual Gearbox Only. Warning Remove the propshaft. The torque tube is heavy. To avoid personal injury or damage to the torque tube, torque tube removal is at Remove the horseshoe clip and pull the propshaft from least a two person operation.
Page 263 Driveshaft (05.01) Driveline (05.00) Installation 4. Install the exhaust manifold. Torque the nuts, in sequence shown, to 18-22 Nm. Warning The torque tube is heavy. To avoid personal injury or Engine Front damage to the torque tube, torque tube removal is at least a two person operation.
Page 264 Driveshaft (05.01) Driveline (05.00) 10. Automatic Gearbox Only. Push the wire clip back into position on the female end, Install the drive plate. Torque bolts to 72 Nm. then connect the male to the female. 11. Manual Gearbox Only. 13. Automatic Gearbox Only. Install the propshaft to the torque tube.
Page 265: Halfshafts (05.05)
Halfshafts (05.05) Driveline (05.00) Driveline (05.00) Halfshafts (05.05) Installation 1. Position the halfshaft through the vertical link. Specifications Torque Figures Description lb. / ft. Halfshaft nut 221.5 Halfshaft to differential Maintenance Halfshaft Repair Operation Time (ROT) Item Code Halfshaft Renew (LH) 05.05.AB (RH)
Page 266 Halfshafts (05.05) Driveline (05.00) 5-5-2 Workshop Manual Issue 3 October 2007...
Page 267: Brake System (06.00)
Brake Systems (06.00) Brake Systems (06.00) Brake System (06.00) Contents Front Disc Brake (06.03)........6-3-1 Brake Booster ............7-1 Description ............. 3-1 Panic Brake Assist........... 7-1 Specifications............3-1 Specifications ............7-2 Maintenance ............3-2 Maintenance............7-2 Brake Caliper (Front and Rear) ....... 3-2 Brake Booster ............
Page 268 Brake Systems (06.00) Brake Systems (06.00) 6-1-2 Workshop Manual Issue 4, November 2008...
Page 269: Description
Front Disc Brake (06.03) Brake Systems (06.00) Brake Systems (06.00) Front Disc Brake (06.03) Description Figure 06.03.01 Specifications Key to Figure 06.03.01 Oils/Greases 1. Brake Hose Assembly. Brake Fluid Castrol Super Response DOT 4 (Not 2. Caliper Bolt silicon based brake fluid). 3.
Page 270: Maintenance
Front Disc Brake (06.03) Brake Systems (06.00) Brake pads Replace the brake pad if there are the conditions that New pad thickness 9.4 mm follow: Minimum lining 2.5 mm There less than one-third of the friction material remains on thickness the brake pad, the vehicle is used regularly and there is a long period before the next service.
Page 271 Front Disc Brake (06.03) Brake Systems (06.00) 6. Install the brake pad wear sensor. Install the left and right shims as recorded at removal. When you install new brake pads, install a new brake pad wear sensor. 4. Remove the sealing plug from the brake-pipe port. CAUTION 7.
Page 272: Brake Discs (Front And Rear)
Front Disc Brake (06.03) Brake Systems (06.00) Brake Discs (Front and Rear) Repair Operation Time (ROT) Item Code Brake Disc Renew (Front) 06.03.CB (Rear) 06.04.CB Removal Put a cloth around the brake reservoir filler neck to absorb spilled brake fluid. 1.
Page 273: Brake Pads (Front And Rear)
Front Disc Brake (06.03) Brake Systems (06.00) Brake Pads (Front and Rear) Repair Operation Time (ROT) Item Code Brake Pads Renew (Front) 06.03.DB (Rear) 06.04.DB Removal The front calipers are shown. Put a cloth around the brake reservoir filler neck to absorb spilled brake fluid.
Page 274: Brake Pad 'Bedding-In
Front Disc Brake (06.03) Brake Systems (06.00) Brake Pad ‘Bedding-in’ Repair Operation Time (ROT) Item Code Bedding-in CAUTION IF YOU DO NOT “BED-IN” NEW BRAKE PADS, THE PERFORMANCE OF THE BRAKES CAN BE DECREASED AND YOU CAN GET BRAKE JUDDER OR SQUEAL. After you install new brake pads, the brake performance can be decreased because the brake discs and pads must be “Bedded-in”.
Page 275: Rear Disc Brakes (06.04)
Rear Disc Brakes (06.04) Brake system (06.00) Brake system (06.00) Rear Disc Brakes (06.04) Description Figure 06.04. 01 Key to Figure 06.04.01 8. Brake Hose Assembly 11.Rear Caliper 14.Brake Pad Sensor Assembly 9. Rear Brake Disc Shield 12.Caliper Bolt 10.Grooved Brake Disc 13.Brake Pad Kit The rear disc brake has a caliper that is attached to the vertical link with two bolts.
Page 276: Specifications
Rear Disc Brakes (06.04) Brake system (06.00) Specifications Oils/Greases Brake Fluid Castrol Super Response DOT 4 (Not silicon based brake fluid) Brake discs Brake Disc Initial Thickness 28.0 mm Brake Disc Minimum 26.0 mm Thickness Brake Disc ‘Runout’ <70 μm measured @ 2 mm in from the brake disc edge.
Page 277: Hand Brake (06.05)
Hand Brake (06.05) Brake Systems (06.00) Brake Systems (06.00) Hand Brake (06.05) Description Figure 06.05.01 Key to Figure 06.05.01 15.Handbrake Lever 18.Handbrake Cable 16.Handbrake Caliper and Pad Assembly 19.Stop Assembly 17.Trunnion 20.Unlock Button The hand brake control lever is installed at the outer side of the driver's seat. When the lever is operated, a cable applies mechanical brakes to each rear wheel.
Page 278: Specifications
Hand Brake (06.05) Brake Systems (06.00) Specifications 4. Remove the two bolts that attach the caliper to the vertical link. Discard the two bolts. Brake pads Minimum lining thickness 6 mm Torque Figures Description lb. / ft. Brake Caliper to Vertical Link 15 then 11.5 then 92°...
Page 279: Brake Pads
Hand Brake (06.05) Brake Systems (06.00) WARNING DO NOT USE COMPRESSED AIR TO REMOVE BRAKE PAD DUST. THE DUST CAN BE DANGEROUS. ALWAYS USE A VACUUM BRUSH OR AQUEOUS BRAKE CLEANER TO REMOVE BRAKE PAD DUST. 4. Carefully clean all contamination from the handbrake system components.
Page 280: Handbrake Cable
Hand Brake (06.05) Brake Systems (06.00) Handbrake Cable 4. Adjust the handbrake cable (Refer to ’Adjustment’, page 6-5-5). Repair Operation Time (ROT) WARNING Item Code BEFORE YOU DRIVE THE VEHICLE, OPERATE THE Handbrake Cable Renew 06.05.DB HAND BRAKE LEVER 2 OR 3 TIMES TO MAKE SURE THAT THE HAND BRAKE OPERATES CORRECTLY.
Page 281: Install
Hand Brake (06.05) Brake Systems (06.00) Adjustment 5. Disconnect the cable from the subframe. 1. Make sure that the handbrake lever is fully released. 2. Release the handbrake cable lock nuts (1) and turn the adjustment fully in. Image - Left Hand Drive vehicle Caution 3.
Page 282 Hand Brake (06.05) Brake Systems (06.00) 6-5-6 Workshop Manual Issue 3, October 2007...
Page 283: Brake Actuation System (06.06)
Brake Actuation System (06.06) Brake System (06.00) Brake System (06.00) Brake Actuation System (06.06) Description There is a sensor installed in the master cylinder that gives brake pressure data to the ABS/DSC module. This data tells Tandem Master Cylinder the system how hard the driver operates the brakes and is used to help the ABS/DSC accurately control the brake pressure.
Page 284: Maintenance
Brake Actuation System (06.06) Brake System (06.00) Maintenance Master Cylinder Repair Operation Time (ROT) Item Code Master Cylinder Renew 06.06.EB Removal 1. Remove the coolant reservoir (LH drive only). This is to give better access. Note that there is an electrical connector on the bottom of the coolant reservoir.
Page 285: Brake Fluid Reservoir
Brake Actuation System (06.06) Brake System (06.00) Brake Fluid Reservoir 2. Attach the master cylinder with new nyloc nuts (x2). Torque the nuts to 25 Nm +/- 4 Nm. Repair Operation Time (ROT) Item Code Brake Fluid Reservoir Renew 06.06.AB 25 Nm.
Page 286: Install
Brake Actuation System (06.06) Brake System (06.00) Install 1. Install new O-rings to the brake fluid reservoir. Apply a thin layer of brake fluid to lubricate the O-rings. 2. Install the brake fluid reservoir to the master cylinder. Ensure correct location of the ‘O’ rings. 3.
Page 287: Brake Bleed - Manual
Brake Actuation System (06.06) Brake System (06.00) Brake Bleed - Manual After a Caliper Replacement Preparation 1. Connect the bleed-bottle tube to the bleed screws of front left and rear left calipers. Open the front left and rear left caliper’s bleed screws. 2.
Page 288 Brake Actuation System (06.06) Brake System (06.00) 6-6-6 Workshop Manual Issue 3, October 2007...
Page 289: 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 290: Specifications
Power Brake System (06.07) Brake System (06.00) Specifications 5. Disconnect the wiring harness plugs (x2). 6. Withdraw the brake booster. Torque Figures Description lb. / ft. Brake Booster Mount 21-24 15.5-18 Maintenance Brake Booster Repair Operation Time (ROT) Item Code Brake Booster Renew RHD 06.07.AB Removal...
Page 291: Concept
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 that has inputs independently from all four of the wheel speed sensors. The ABS module monitors the signals from the sensors to calculate the brake slip and the acceleration or deceleration of the wheels.
Page 292: System Overview
Anti-lock Braking System (ABS) (06.09) Brake system (06.00) this process is to find how the vehicle should respond to The throttle is put in the correct position to give the correct driver demand (the ideal response) and how it actually does torque.
Page 293: Engine Intervention
Anti-lock Braking System (ABS) (06.09) Brake system (06.00) Engine Intervention Brake Intervention This function increases the pressure in the brake caliper of If wheel-slip occurs the ABS/DSC module calculates the the wheel that slips. To do this, it closes the separation valve torque that needs to be applied by the engine to reduce the and the inlet valve of the wheel that does not slip and wheel-slip (this torque will not exceed the driver’s demand).
Page 294: Maintenance
Anti-lock Braking System (ABS) (06.09) Brake system (06.00) Maintenance 6. Remove the three bolts (1) that attach the modulator mounting (see the figure below). ABS Modulator - Remove and Install Repair Operation Time (ROT) Item Code ABS Modulator - Remove and Install RHD 06.06.CB Remove WARNING...
Page 295: Install
Anti-lock Braking System (ABS) (06.09) Brake system (06.00) Install 1. Install the modulator to its mounting bracket. Attach it with the three bolts (2)(Refer to the Figure that follows). 2. Torque the three M6 bolts (2). 9. Remove all signs of brake fluid from the modulator and adjacent area.
Page 296 Anti-lock Braking System (ABS) (06.09) Brake system (06.00) 6-9-6 Workshop Manual Issue 3, October 2007...
Page 297 Transmission (07.00) Contents Automatic Transaxle (07.01)........7-1-2 Remove .............. 3-3 Description ............. 1-2 Install..............3-4 Cooling ..............1-2 Differential Output Seal (Left Side)......3-5 Mechatronik module ..........1-2 Remove .............. 3-5 Specifications............1-3 Install..............3-6 Gearbox ..............1-3 Differential Output Seal (Left Side)......3-7 Differential.............
Page 298: Transmission (07.00)
Automatic Transmission (07.01) Transmission (07.00) Transmission (07.00) Automatic Transaxle (07.01) transmission fault-finding. This monitors all components that can effect vehicle Description emissions. The ZF 6HP26 automatic gearbox has the following There are also more fault-find functions to make sure that that features: all malfunctions can be repaired quickly by maintenance staff.
Page 299: Specifications
Automatic Transmission (07.01) Transmission (07.00) 1. Hydraulic Module 5. Position Switch 9. Adaptor 2. Electronic Module 6. Turbine Speed Sensor 10. Suction Port 3. Output Speed Sensor 7. Solenoid Valve 4. Temperature Sensor 8. Discharge Port Specifications Transmission oil Gearbox The ZF 6HP26 automatic transmission is ‘filled for life’...
Page 300: Differential
Automatic Transmission (07.01) Transmission (07.00) Differential WARNING DO NOT BREATHE EXHAUST FUMES. EXHAUST Type FUMES CONTAIN CARBON MONOXIDE. CARBON Graziano AM803D MONOXIDE IS A DANGEROUS GAS THAT IS COLOURLESS AND ODOURLESS. IT CAN CAUSE Weight UNCONSCIOUSNESS AND CAN KILL. Complete with differential oil - 47.25 kg (104 lbs) approx 2.
Page 301: Automatic Transaxle
Automatic Transmission (07.01) Transmission (07.00) Automatic Transaxle • The rear wheels do not move for a minimum of 2 minutes before you do the oil level check and during the Repair Operation Time (ROT) procedure, for example: operate the hand brake Item Code •...
Page 302: Install
Automatic Transmission (07.01) Transmission (07.00) Mechatronik Unit Install 1. Use applicable lifting equipment, for example: a Repair Operation Time (ROT) hydraulic ramp and sling, to hold the transaxle from Item Code above. Mechatronik Unit Renew 07.00.AD 2. Put the transaxle in position in the subframe. Remove 3.
Page 303: Install
Automatic Transmission (07.01) Transmission (07.00) 6. Remove the oil thermostat with the gearbox side coolant 11. Remove and discard the seals for the the Mechatronik pipes (Refer to ’Thermostat (Automatic Gearbox)’, page unit. 7-2-2). Install 7. Remove the gearbox Capacitor. 1.
Page 304 Automatic Transmission (07.01) Transmission (07.00) 4. Push in the new electrical connector socket into position 11. Connect the coolant pipes (1 and 2) to the gearbox. with the Mechatronik unit screw plug attached. Attach it Torque the bolt to 20-25 Nm (see Figure below). with the retaining clip.
Page 305: Differential
Automatic Transmission (07.01) Transmission (07.00) Differential Repair Operation Time (ROT) Item Code Differential Renew 05.02.AB Remove 1. Remove the rear subframe with the transaxle (Refer to ’Rear Subframe’, page 2-1-4). 2. Use appliable lifting equipment, for example: a hydraulic ramp and a sling to hold the transaxle from above.
Page 306: Remove
Automatic Transmission (07.01) Transmission (07.00) 6. Install the transaxle to it’s mounting brackets. 7. Attach the transaxle with the four bolts. 8. Torque the four bolts on each mount to 20-30 Nm. 01-05-011 9. Remove the four bolts that attach the output shaft cover. 9.
Page 307: Differential Output Seal (Right)
Automatic Transmission (07.01) Transmission (07.00) 11. Make sure that the drain plug is installed. Torque the drain plug to 49 Nm. Fill the differential with the specified oil (Refer to ’Specifications’, page 7-1-3). 12. Remove the seal. Install 1. Install a new seal. Push the seal in until it is against the lip in the casing.
Page 308 Automatic Transmission (07.01) Transmission (07.00) 16. Remove the oil seal. 13. Remove the circlip. 14. Remove the output shaft with the bearing. Install 1. Install a new oil seal. Push the seal in until it is against the lip in the casting. Apply a thin layer of grease to the lip of the seal.
Page 309 Automatic Transmission (07.01) Transmission (07.00) 4. Install two new O rings. 14. Install the undertray. 5. Install the differential housing cover. 6. Apply Loctite 242 to the threads of the 12 bolts. Install the 12 bolts and torque the bolts to 35 Nm. 7.
Page 310: Differential Oil Filter
Automatic Transmission (07.01) Transmission (07.00) Differential Oil Filter Differential Speed Sensor Repair Operation Time (ROT) Repair Operation Time (ROT) Item Code Item Code Differential Oil Filter Renew Differential Speed Sensor Renew Remove Remove 1. Remove the rear undertray. 1. Remove the rear undertray (1). 2.
Page 311: Transmission Cooling (07.02)
Transmission Cooling (07.02) Transmission (07.00) Transmission (07.00) Transmission Cooling (07.02) 6. Remove the two bolts that attach thePAS cooler. Move the PAS cooler to one side. Specifications Thermostat °C °F Oil cooler thermostat range 74°- 88° 165° - 190° (Auto only) Torque Figures Description lb.
Page 312: Install
Transmission Cooling (07.02) Transmission (07.00) Thermostat (Automatic Gearbox) 9. Remove the four bolts (1) that attach the cooler matrix. Remove the cooler matrix. Repair Operation Time (ROT) Item Code Thermostat (Automatic Gearbox) Renew 07.02.FF Remove WARNING THE TRANSMISSION OIL WILL BE HOT AFTER OPERATION.
Page 313: Install
Transmission Cooling (07.02) Transmission (07.00) Oil Cooler (Automatic Transaxle Install Differential) 1. Install the thermostat and thermostat bracket assembly to the gearbox. Repair Operation Time (ROT) 2. Connect the four cooling pipes (1). Make sure that the Item Code O-ring is correctly installed in each pipe union. Oil Cooler (Automatic Transaxle 07.02.BA Torque each union to 20 Nm.
Page 314: Oil Cooler (Manual Transaxle)
Transmission Cooling (07.02) Transmission (07.00) Oil Cooler (Manual Transaxle) Repair Operation Time (ROT) Item Code Oil Cooler (Manual Transaxle) Renew 07.02.FC Remove 1. Disconnect the coolant pipes. Some oil will drain when the pipes are removed. Seal the open ends of the pipes to prevent contamination.
Page 315: Manual Transmission (07.03)
Manual Transmission (07.03) Transmission (07.00) Transmission (07.00) Manual Transmission (07.03) Description 11. Speed Sensor 12. Breather Pipes 13. Sump Plug The Graziano AM803T transaxle installed to this vehicle has a six speed transmission with synchromesh on all gears. Gear selection is by a twin cable system (shift and select) that operates a bellcrank and H-gate.
Page 316: Specifications
Manual Transmission (07.03) Transmission (07.00) Specifications Maintenance Oil Check and Fill Type If there is an oil leak from the transaxle cooling system you Graziano AM803T transaxle with: must: • Integrated Bellcrank Assembly • repair the leak • Integrated Reverse Switch •...
Page 317: Transaxle
Manual Transmission (07.03) Transmission (07.00) Transaxle 6. Disconnect the electrical connector (1) on the right side of the transaxle. Repair Operation Time (ROT) 7. Disconnect the electrical connector (2) on the left side Item Code of the transaxle. Manual Transaxle Renew 07.03.CB Remove 1.
Page 318: Install
Manual Transmission (07.03) Transmission (07.00) 10. Use the applicable lifting equipment, for example: a 3. Move the transaxle to align with the torque tube. hydraulic jack and a sling to hold the transaxle. 4. Install the eight bolts and torque to 43-57 Nm. 11.
Page 319: Differential Output Seal (Left Side)
Manual Transmission (07.03) Transmission (07.00) Differential Output Seal (Left Side) Repair Operation Time (ROT) Item Code Differential Output Seal (Left) Renew If you need to replace both left and right seals at the same time, change the LH seal first. When replacing the right seal the left output shaft will hold the differential unit.
Page 320: Install
Manual Transmission (07.03) Transmission (07.00) Install 9. Remove the four bolts that attach the output shaft cover. 1. Install a new seal. Push the seal in until it is against the lip in the casing. Apply a thin layer of grease to the lip of the seal.
Page 321: Differential Output Seal (Left Side)
Manual Transmission (07.03) Transmission (07.00) Differential Output Seal (Left Side) 9. Remove the two O-rings. Repair Operation Time (ROT) Item Code Differential Output Seal (Right) Renew Remove 1. Disconnect the vehicle battery. 2. Raise the vehicle and make safe. 3. Remove the right road wheel and road wheel arch liner. 4.
Page 322: Install
Manual Transmission (07.03) Transmission (07.00) Differential (Limited Slip) Install 1. Install a new seal. Push the seal in until it seats against Repair Operation Time (ROT) the lip in the casting. Smear the lip with a small amount Item Code of grease.
Page 323: Install
Manual Transmission (07.03) Transmission (07.00) 8. Remove the differential cover. Install service tool (No. ) to differential output shaft. Remove bolts (x12). Withdraw the differential cover. Discard the ‘O’ rings (x2). 9. Remove the differential. The differential may come out with the differential cover or it may remain in the differential housing located on the L/H output shaft.
Page 324 Manual Transmission (07.03) Transmission (07.00) 7-3-10 Workshop Manual Issue 3 October 2007...
Page 325: Automatic Control System (07.05)
Automatic Control System (07.05) Transmission (07.00) Transmission (07.00) Automatic Control System (07.05) Description Transmission Controls The transmission shift console is installed in the centre console. There are four push-buttons installed in the transmission shift console that are used to electrically select P,R,N and D. Electrical and electronic data is transmitted from either the push-buttons or the "TouchTronic"...
Page 326: Parking Lock
Automatic Control System (07.05) Transmission (07.00) Drive (D) - TouchTronic The two paddles behind the steering wheel are used to change the gears. The left paddle (-) changes the gear down and the right (+) paddle changes the gear up. The up and down gear change positions are controlled so that the engine cannot go too fast.
Page 327: Hydraulic Shift Control Unit
Automatic Control System (07.05) Transmission (07.00) There is a mechanical spring system in the transmission that engages and holds the parking lock. It is released electro- mechanically. All of the drive positions for the transmission are operated electrically. There is no detent disc in the transmission.
Page 328 Automatic Control System (07.05) Transmission (07.00) Shoes and Foot Earthing Straps Put on electrically conductive shoes when you work in an ESD protection zone. This is very important if you cannot wear a wrist band. Because there is a risk of high contact voltages, the shoes must have a resistance of 0.1 MOhm or less. Transmission Control Module (TCM) The transmission control module (TCM) and its input and output network controls the transmission operations that follow: •...
Page 329: Tcm Monitoring Functions
Automatic Control System (07.05) Transmission (07.00) The Accelerator Pedal Position (APP) sensor The accelerator pedal position (APP) sensor is a potentiometer on the accelerator pedal. It senses the position of the accelerator pedal and sends this data to the TCM. The APP sensor is used to schedule the gear changes and the Torque Converter Clutch (TCC) lock-up.
Page 330 Automatic Control System (07.05) Transmission (07.00) Watchdog Monitoring The watchdog monitoring system has two functions: • It makes sure that control of the output is stopped when the solenoid supply transistor is connected. • It does a check of the correct operation of the safety circuit. During initialization, the watchdog operates the solenoid supply transistor to make sure that it is possible to prevent the control of the pressure regulator and the solenoid valves.
Page 331 Automatic Control System (07.05) Transmission (07.00) The Lock-up function will operate in all gears, but usually it is only used in third, fourth, fifth and sixth gears. When it operates, the lock-up clutch in the torque converter is modulated to let it slip a small amount under control. This gives a better gear change quality.
Page 332: Tcm Supply Voltage
Automatic Control System (07.05) Transmission (07.00) Torque Converter Clutch Hydraulic Pressure Regulation The TCM gives a +12 V supply to the No. 6 pressure regulator. The regulator operates when the opposite connection of the operating winding is grounded. The hydraulic pressure is operated by pulse width modulation (PWM) of the time that the pressure regulator is switched on and off (the duty cycle).
Page 333 Automatic Control System (07.05) Transmission (07.00) Figure 7-05-003 - Shift-By-Wire Diagram Key to Figure 07-05-003 - Shift-By-Wire Diagram 1. Driver Input P Park Hard wired 2. Centre Console R Reverse Hard wired Park or No Park 3. Steering Wheel N Neutral Serial Backup Line 4.
Page 334: Transmission Plug Pin Assignment
Automatic Control System (07.05) Transmission (07.00) Transmission Plug Pin Assignment Assigned to Notes Series line Serial Backup Line EMS CAN L CAN low ISO K K line (for example application) Not in use Digital input Not in use Digital input CAN H CAN high Heartbeat Supply...
Page 335: Clutch (08.00)
Clutch (08.00) Contents Clutch Assembly (08.01)........8-1-2 Description ............... 1-2 Specifications ............1-2 Maintenance............. 1-2 Clutch Assembly ............ 1-2 Remove............... 1-2 Installation ............1-3 Issue 3, October 2007 Workshop Manual 8-1-1...
Page 336 Clutch Assembly (08.01) Clutch (08.00) Clutch Assembly (08.01) 3. Remove the rear road wheel(s) and road wheel arch liners. Description 4. Remove the front and rear undertrays and the shear plate. The clutch assembly is a balanced unit consisting of a Lower the front undertray to reveal the air intake for the flywheel, clutch friction plates and clutch cover.
Page 337 Clutch Assembly (08.01) Loosely install new flywheel mounting bolts (x8) and Installation hand tighten. • If the new clutch assembly is bolted to the flywheel, Tighten the bolts in the remove the new clutch assembly from flywheel. Note sequence illustrated. Continue position of clutch assembly to flywheel.
Page 338 Clutch Assembly (08.01) 4. Insert the clutch alignment tool (Refer to ’303-667 (Clutch Alignment)’, page 20-1-5) through the clutch assembly. Offer this assembly to the flywheel and insert the alignment tool into the crankshaft pilot bearing. Caution The flywheel and pressure plate are a balanced assembly.
Page 339: 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) ........9-3-1 Specifications............3-1 Maintenance ............3-1 Exhaust System ............3-1 Removal.............. 3-1 Installation ............3-2 Issue 3, October 2007 Workshop Manual 9-1-1...
Page 340: Exhaust Overview
Exhaust Overview Exhaust System (09.00) Exhaust System (09.00) Exhaust Overview The exhaust system consists of two six-branch manifolds, four primary catalytic converters, eight oxygen sensors, two secondary catalytic converters and a single variable flow silencer assembly. Exhaust gasses flow from the exhaust manifolds, through the primary catalysts, through the secondary catalysts and on to the rear silencer assembly.
Page 341: 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 342 Silencer Assembly (09.01) Exhaust (09.00) 9-1-4 Workshop Manual Issue 3, October 2007...
Page 343: Pipes And Supports (09.03)
Pipes and Supports (09.03) Exhaust System (09.00) Exhaust System (09.00) Pipes and Supports (09.03) 5. Remove LH and RH rear pipes. Remove subframe cross brace. Specifications Release clamps (2) Release LH and RH pipe hangers from body. Torque Figures Withdraw LH and RH rear pipes through the Description lb.
Page 344: Installation
Pipes and Supports (09.03) Exhaust System (09.00) 7. Remove the catalysts. Release bolts (x3). Withdraw catalyst. Repeat for second catalyst. Installation Use a proprietary exhaust sealant around all clamp joints prior to securing loosely. Use new manifold flange gaskets. 1. Install, loosely, the LH and RH catalysts. 2.
Page 345: Fuel (10.00)
Fuel (10.00) Contents Fuel Tank and Lines (10.01) ........10-1-2 Description ............. 1-2 Fuel Tank............... 1-3 Fuel Pumps............1-4 Jet Pumps .............. 1-4 Filler Neck and Check Valve ........1-5 Valves and Sensors..........1-5 Fuel System Schematic ........... 1-6 Evaporative Loss System......... 1-6 System Operation ..........
Page 346: 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 two fuel pumps, controlled by the fuel pump driver modules, are run to supply fuel through two in-tank filters to the two fuel rails (Refer to ’Fuel Charging System (03.04)’, page 3-4-1). Each fuel rail is installed with six fuel injectors.
Page 347: 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 pumps, internal fuel filters, a sender unit and an ‘on board refuelling vapour recovery’ system. High Pressure Roll Over Valve Feed to the Jet Pump Roll Over Valve Fuel Limit Vent Valve...
Page 348: Fuel Pumps
Fuel Tank and Lines (10.01) Fuel (10.00) Fuel Pumps Fuel Pumps The two modular fuel pumps are immersed in the base of the fuel tank. The pumps can deliver up to 150 litres / hour. The in-tank fuel lines connect to the external lines using two quick-fit connectors in the base of the fuel tank. 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 349: Filler Neck And Check Valve
Fuel Tank and Lines (10.01) Fuel (10.00) Filler Neck and Check Valve Valves and Sensors Incoming fuel passes through a check valve at the base of the filler neck. This valve is normally held closed by light spring pressure. The valve opens under the pressure of incoming fuel and closes again when fuel flow ceases.
Page 350: Fuel System Schematic
Fuel Tank and Lines (10.01) Fuel (10.00) Fuel System Schematic It includes the positive crankcase ventilation and vapour recovery systems. 1. Oil separator 2. PCV valve 3. Check valve 4. Relief valve 5. Vapour management valve 6. Fuel tank pressure transducer 7.
Page 351 Fuel Tank and Lines (10.01) Fuel (10.00) Canister Close To Carbon Filter Carbon Canister Valve Canister Close Valve Filter Clean Air On-Board Refuelling Vapour Recovery Normal Fuel Fill - Air displaced from the fuel tank during filling can only exit via the fuel level vent valve and be forced All of the vapour displaced from the tank by refuelling passes through the carbon canister.
Page 352: Safety Precautions
Fuel Tank and Lines (10.01) Fuel (10.00) Safety Precautions Specifications Operations on fuel system result in fuel liquid and vapour Pump Pressure being present in the working environment. This presents a Nominal pump pressure 40 psi (2.7 bar) above inlet very serious risk and the following precautions must be manifold pressure.
Page 353: Maintenance
Fuel Tank and Lines (10.01) Fuel (10.00) Maintenance Remove Volante Models Only: Fuel System 1. Do the applicable steps of procedure 10.01.FB to get access and drain the fuel tank (Refer to ’Fuel Tank - WARNING NEVER DO WORK ON THE FUEL SYSTEM OF A HOT Remove and Install’, page 10-1-11).
Page 354 Fuel Tank and Lines (10.01) Fuel (10.00) • While you hold the two buttons in, pull the connector 6. Put the outer attachment bracket (item 5) for the filter off the filter. (item 3) over the assembly. 7. Use a bradawl or a similar tool to align the holes for the attachment screw.
Page 355: Fuel Tank - Remove And Install
Fuel Tank and Lines (10.01) Fuel (10.00) Fuel Tank - Remove and Install Repair Operation Time (ROT) Item Code Fuel Tank - Remove and Install 10.01.FB Fuel Tank - Remove for Access and 10.01.GA Install Remove WARNING BEFORE YOU DO WORK ON THE FUEL SYSTEM DISCONNECT THE EARTH LEAD FROM THE VEHICLE BATTERY.
Page 356 Fuel Tank and Lines (10.01) Fuel (10.00) Figure 1 7. Use a bowser to pump the fuel out of the fuel tank. Note: Some fuel will remain in the tank. Figure 3 14. Seal the filler neck on the tank. All Vehicles: 15.
Page 357 Fuel Tank and Lines (10.01) Fuel (10.00) Install 17. Release the clip that attaches the hose to the DTML and disconnect the hose. WARNING WARNING READ AND OBEY ALL FUEL RELATED INSTRUCTIONS THE FUEL TANK IS VERY HEAVY WHEN IT IS FULL OF AT THE START OF THIS CHAPTER AND IN THE FUEL.
Page 358: Fuel Pump - Remove And Install
Fuel Tank and Lines (10.01) Fuel (10.00) 21. Do a check of the fuel system for leaks. 2. Remove the M5 screw (item 1) that attaches the fuel filter brackets (items 2 and 3) of the filter for the WARNING applicable fuel pump (pump) side (refer to Figure 1).
Page 359 Fuel Tank and Lines (10.01) Fuel (10.00) 5. Disconnect the cross-feed fuel pipes. (items 1 and 2) (Refer to Figure 3). Figure 4 8. Remove the fuel pump. Install Figure 3 1. Put the fuel pump in position in its mounting. 6.
Page 360: Carbon Cannister Assembly - Remove And Install
Fuel Tank and Lines (10.01) Fuel (10.00) 11. Install the M5 attachment screw to attach the filter and 3. Disconnect the hose. brackets. Do not tighten the screw at this step. 4. Push in and hold the two buttons on the quick-release 12.
Page 361: Sender Assembly For The Fuel Tank
Fuel Tank and Lines (10.01) Fuel (10.00) 3. If applicable, use the Oetiker tool to close the pipe 2. Cut the “fir-tree” cable-tie (1) that attaches the sender clamp. harness (2) and the hose to the bracket (3). 4. Push the quick-release connector on to the outlet pipe of the fuel tank.
Page 362: Fuel Level Vent-Valve Assembly
Fuel Tank and Lines (10.01) Fuel (10.00) 13. Do a check of the fuel system for leaks. 5. Discard the Oetiker pipe clamp. 6. Release the two tabs that attach the valve assembly to its WARNING mounting bracket. DO NOT CONNECT THE BATTERY AND SET THE IGNITION TO ON UNTIL ALL WORK ON THE FUEL 7.
Page 363: Roll Over Valve Assembly, Fuel Vapour
Fuel Tank and Lines (10.01) Fuel (10.00) Roll Over Valve Assembly, Fuel Vapour - 6. Put the clamp plate in position over the studs around the access hole. Left-Side - Remove and Install 7. Put a new seal for the service cover in position on the tank.
Page 364 Fuel Tank and Lines (10.01) Fuel (10.00) 10-1-20 Workshop Manual Issue 5, November 2009...
Page 365: Steering (11.00)
Steering (11.00) Contents Steering Gear (11.01) ..........11-1-2 Diagnostics ............. 1-2 Symptom Chart............1-2 Specifications............1-4 Maintenance ............1-4 Wheel Bearing Inspection ........1-4 Ball Joint Inspection ..........1-4 Track-Rod Ends............1-5 Removal.............. 1-5 Installation ............1-5 Steering Rack ............1-6 Removal..............
Page 366: Steering Gear (11.01)
Steering Gear (11.01) Steering (11.00) Steering (11.00) Steering Gear (11.01) Upper Cowl Steering Column Steering Angle Sensor Bulkhead Seal Switch Gear Assay I nt e rm e dia t e Sha ft Pressure Transducer Power Steering Module Assay PAS Oil Reservoir Steering Rack Cooling Loop Track Rod Ends...
Page 367 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 368: Specifications
Steering Gear (11.01) Steering (11.00) Symptom Possible Cause Action Excessive steering Low power steering pump fluid. Fill as required. Check for system leaks. efforts required to Damaged accessory drive belt tensioner. New accessory drive belt tensioner. turn corners and Hose or oil cooler external leak. New hose or oil cooler as required.
Page 369: Track-Rod Ends
Steering Gear (11.01) Steering (11.00) 4. While an assistant pulls and pushes the top of the road wheel, observe the relative movement between the ball joint and the suspension upper arm. Any lateral movement indicates a worn or damaged upper ball joint. Install new components as required.
Page 370: Steering Rack
Steering Gear (11.01) Steering (11.00) Steering Rack Repair Operation Time (ROT) Item Code Steering Rack Renew 11.02.DB Removal 1. Disconnect the vehicle battery. Caution Failure to centre the steering wheel and rack during reassembly may cause damage to the restraint bag clock-spring and also may cause difficulties in attaining 001-11-005 correct alignment of the steering wheel in the straight...
Page 371 Steering Gear (11.01) Steering (11.00) Install the front subframe (Refer to ’Front Subframe’, 3. Install L/H and R/H rod ends to the vertical link. page 2-1-2). Connect the steering rack pipe work. 70 Nm 9-12 Nm 4. Recheck both the steering wheel and rack are accurately centred.
Page 372 Steering Gear (11.01) Steering (11.00) 11-1-8 Workshop Manual Issue 4, November 2008...
Page 373: Power Steering (11.02)
Power Steering (11.02) Steering (11.00) Steering (11.00) Power Steering (11.02) The power steering system is hydraulically driven and contains a speed sensitive rack and pinion steering gear (ZF Servotronic II ®). Power assistance is generated by an engine driven vane pump, operating at a constant flow rate. The level of assistance is controlled electronically via an ECU, which receives a vehicle speed signal from the speedometer.
Page 374: Specifications
Power Steering (11.02) Steering (11.00) Specifications Item Data Pump Pressure (max) 116 +/-4 bar Turns lock-to-lock Overall steering ratio 17:1 Turning Circle (Kerb 11.5m To Kerb) Fluids 33270 Texaco Cold Climate Power Steering Fluid 14315G Capacity 1.3 ltr. Toe Settings (Refer to ’Road Wheel Alignment (04.00)’, page 4-0-2) Maintenance...
Page 375: Steering Column (11.04)
Steering Column (11.04) Steering (11.00) Steering (11.00) Steering Column (11.04) 7. Turn the steering wheel to get access to the top screw in the front face of the shroud at the left side . Description Note: The top screw goes through the top shroud and a tab on the bottom shroud to attach it.
Page 376 Steering Column (11.04) Steering (11.00) 9. Install the two screws at the right side of the front face of the column shrouds. 10. Put the lower panel on the driver’s side of the instrument panel and engage the seven clips. Steering Column Gaiter - Renew Repair Operation Time (ROT) Item...
Page 377 Steering Column (11.04) Steering (11.00) 10. Put the driver’s seat and the steering column in their initial positions. Steering Column - Remove and Install Repair Operation Time (ROT) Item Code Steering Column (Upper) Renew 11.04.CB Removal 1. Operate the driver’s seat to it’s lowest and most rearward position.
Page 378 Steering Column (11.04) Steering (11.00) Installation 13. Connect the vehicle battery. Top and Bottom Shrouds for the Steering 1. Do the steps that follow to install the upper column: Connect the intermediate shaft to the upper column. Column - Remove and Install Put the steering column in position onto its mount.
Page 379 Steering Column (11.04) Steering (11.00) Remove the Top Shroud 6. Lower the vehicle. 7. Remove the top and bottom shrouds from the steering 1. Release the steering column adjustment lever. column (Refer to ’Top and Bottom Shrouds for the 2. Move the steering wheel to the longest column position. Steering Column - Remove and Install’, page 11-3-4).
Page 380 Steering Column (11.04) Steering (11.00) 20. Put the driver’s seat and the steering column in their initial positions. 11-4-6 Workshop Manual Issue 4, November 2008...
Page 381: Steering Column Switches (11.05)
Steering Column Switches (11.05) Steering (11.00) Steering (11.00) Steering Column Switches (11.05) Maintenance Steering Column Stalk Assembly Switch- Renew (Pre-08 MY Only) Ignition Switch (Pre-08 MY Only) - Remove and Install Repair Operation Time (ROT) Item Code Repair Operation Time (ROT) Steering Column Stalk Assembly 11.06.BK Item...
Page 382: Column Controls
Steering Column Switches (11.05) Steering (11.00) Cruise Control Switch - Renew 8. Automatic transmission only. Remove the four screws and release the paddle shift Repair Operation Time (ROT) assembly. Item Code Disconnect the electrical connector and remove Cruise Control Switch - Renew 11.06.BL paddle shift.
Page 383 Steering Column Switches (11.05) Steering (11.00) Airbag Rotary Coupler Assembly - 8. Move the airbag module to get access to the two electrical connectors. Remove and Install Repair Operation Time (ROT) Item Code Airbag Rotary Coupler Assembly - 11.06.CM Remove and Install Remove For Pre-08MY vehicles: 1.
Page 384 Steering Column Switches (11.05) Steering (11.00) 15. Apply tape to hold the rotary coupler in its central 21. Remove the electrical connector (1) from the rotary position. coupler. Figure 5 16. Remove the top and bottom steering column shrouds (Refer to ’Top and Bottom Shrouds for the Steering Column - Remove and Install’, page 11-4-4).
Page 385 Steering Column Switches (11.05) Steering (11.00) 17. Turn the steering wheel to get access to install one of the two airbag module M6 attachment screws. 18. Install the first M6 attachment screw. 19. Turn the steering wheel to get access to install the second airbag module M6 attachment screw.
Page 386 Steering Column Switches (11.05) Steering (11.00) 11-5-6 Workshop Manual Issue 4, November 2008...
Page 387: Steering Wheel (11.06)
Steering Wheel (11.06) Steering (11.00) Steering (11.00) Steering Wheel (11.06) 7. Remove the M10 steering wheel attachment acrew. Specifications Torque Figures Description lb / ft. Steering Wheel Airbag Module Attachment Screws Maintenance Steering Wheel - Remove and Install Repair Operation Time (ROT) Item Code Steering Wheel - Remove and Install...
Page 388 Steering Wheel (11.06) Steering (11.00) For 08MY vehicles or newer: 4. Install and torque the first M6 attachment screw.Turn the steering wheel to get access to install the second 2. Put the Emotion Control Unit (ECU) into the docking airbag module M6 attachment screw. station at position 2 to release the ESCL..
Page 389: Climate Control (12.00)
Climate Control (12.00) Contents Body Ventilation (12.01)........12-1-2 Leak Detection..........3-10 Air Intake & Distribution System......1-2 System Pressure Fault Classification...... 3-10 Maintenance ............1-3 A/C Unit .............. 3-11 Actuators ............... 1-3 Removal............3-11 Removal.............. 1-3 Installation ............3-12 Install..............1-3 Heater Matrix ............
Page 390: Body Ventilation System (12.01)
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 391: Maintenance
Body Ventilation system (12.01) Climate Control (12.00) Maintenance The lower actuator on the A/C unit requires to be firstly Actuators removed from the A/C unit. Repair Operation Time (ROT) Item Code Actuators Renew The A/C and blower unit assembly uses three actuators •...
Page 392: Inspection
Body Ventilation system (12.01) Climate Control (12.00) Air Mix Actuator Airflow Mode Actuator Inspection Inspection 1. Connect the battery positive voltage to the Airflow 1. Connect the battery positive voltage to Air Mix Actuator Mode Actuator terminal 6 (or 7), and ground to terminal terminal 6 (or 7), and ground to terminal 7 (or 6).
Page 393: Heater System (12.02)
Heater System (12.02) Climate Control (12.00) Heater System (12.02) Inspection 1. Connect the battery positive voltage to blower motor Maintenance terminal 1, ground to terminal 2, and then verify that Blower Motor the blower motor operates smoothly. Repair Operation Time (ROT) Item Code Blower Motor Renew...
Page 394 Heater System (12.02) 12-2-2 Workshop Manual Issue 3 October 2007...
Page 395: 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 Description Item Description Condenser Low-side charge. Trinary switch Blower Unit. Compressor assembly Switch, A/C Cut-Off. High-side charge port Expansion valve. Receiver drier. A/C Unit. Major Components Condenser Compressor...
Page 396: Expansion Valve
Air Conditioning (A/C) System (12.03) Climate Control (12.00) Expansion Valve The expansion valve is located on the outside of the A/C unit and comprises of a diaphragm, connected by a capillary tube to a temperature sensing bulb, which regulates the valve according to temperature variations at the evaporator outlet pipe.
Page 397: Refrigerant System
LUBRICANT VAPOR. EXPOSURE MAY IRRITATE EYES, recovery / recycling / recharging unit, never charge the NOSE AND THROAT. ALSO, DUE TO refrigerant. ENVIRONMENTAL CONCERNS, ASTON MARTIN RECOMMEND THE USE OF A RECOVERY / RECYCLING Caution / RECHARGING UNIT WHEN DRAINING R-134A If there is too much or too little refrigerant from the FROM THE A/C SYSTEM.
Page 398: Operation
Air Conditioning (A/C) System (12.03) Climate Control (12.00) Specifications Operation 1. The Compressor (1) draws low pressure, low Refrigerant and Lubricant temperature, refrigerant vapour from the evaporator (5) and compresses it, raising the refrigerant pressure and Refrigerant R-134a temperature. Compressor Lubricant ND8 (DENSO) 2.
Page 399: Diagnostics
Air Conditioning (A/C) System (12.03) Climate Control (12.00) Diagnostics Electrical Connectors A/C Module (C0792) Pin Specification V Battery (from CCM) V Ignition (from comfort relay) Recirculation acutuator Blank Air flow mode actuator (input) Solar sensor (input) Ambient Temperature sensor Engine coolant temperature (input) Ref.
Page 400: Dtc Inspection
Air Conditioning (A/C) System (12.03) Climate Control (12.00) A/C Module (C0791) Pin Specification Air flow mode actuator (output) Temperature actuator (output) Blank Blank Blank A/C On (A/C pressure sensor) Blank Recirculation actuator (output) Blank Blank Temperature level (RHD) Blower speed regulator (Output) Air flow mode actuator (output) Temperature actuator (output) Blank...
Page 401 Air Conditioning (A/C) System (12.03) Climate Control (12.00) Fault Code Definition Bad response data - fan speed. Bad response data - recirculation. Serial communications error – header. Serial communications error – checksum. Serial communications error – overrun. Serial communications error – framing. Serial communications error –...
Page 402: 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 403: 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 404: 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 405: A/C Unit
Air Conditioning (A/C) System (12.03) Climate Control (12.00) A/C Unit Repair Operation Time (ROT) Item Code A/C Unit Renew 12.03.EB Removal 1. Connect the AMDS and record any logged fault codes in the A/C system. 2. Disconnect the vehicle battery. 3.
Page 406: Heater Matrix
Air Conditioning (A/C) System (12.03) Climate Control (12.00) 9. Unlatch the A/C unit from the defrost air duct (Push the 5. Remove the IP (Refer to ’Instrument Panel (IP) (01.12)’, A/C unit up into the IP). Withdraw the A/C unit. page 1-12-1).
Page 407 Air Conditioning (A/C) System (12.03) Climate Control (12.00) 7. Remove the blower unit to A/C unit adaptor and pipe 8. Remove the pipe clips (x2) that secure the heater pipes. locator. Remove the foam. 9. Withdraw the heater matrix. Remove the pipe location plate (screws x4). Part the pipe location plate and withdraw.
Page 408: Evaporator
Air Conditioning (A/C) System (12.03) Climate Control (12.00) 5. Install the blower unit. Torque bolts to 10-13 Nm. 5. Remove the expansion valve 6. Install the IP (Refer to ’Instrument Panel (IP) (01.12)’, Remove protective material from around the page 1-12-1). expansion valve.
Page 409: A/C Compressor
Air Conditioning (A/C) System (12.03) Climate Control (12.00) A/C Compressor 6. Remove the clips (x2) that secure the evaporator temperature sensor element to the evaporator. Repair Operation Time (ROT) Item Code A/C Compressor Renew 12.03.AB Removal 1. Disconnect the vehicle battery. 2.
Page 410 Air Conditioning (A/C) System (12.03) Climate Control (12.00) Installation 6. Remove the A/C pipes. Discard the O-rings. Install suitable blanking plugs. If replacing a faulty A/C compressor with internal mechanical damage, also replace the receiver drier which could also be contaminated with mechanical debris. 1.
Page 411: Condenser
Air Conditioning (A/C) System (12.03) Climate Control (12.00) 5. Install the accessory drive belt (Refer to ’Accessory Drive 6. Remove bolts (x2). System (03.05)’, page 3-5-1). Conditioning Compressor 036-8-022 6. Connect the vehicle battery. 7. Withdraw the condenser upwards. 7. Install the road wheel arch liner and road wheel (Refer Installation to ’Torque Tightening of Road Wheel Nuts’, page 4-4- If a new condenser is to be installed ensure the correct...
Page 412: Receiver Drier Assembly
Air Conditioning (A/C) System (12.03) Climate Control (12.00) Receiver Drier Assembly 5. Carry out A/C system actuator check and functional check to ensure correct operation (Refer to ’A/C System Repair Operation Time (ROT) Testing’, page 12-3-9). Item Code Power Transistor A/C Receiver Drier Renew 12.03.DB Inspection...
Page 413: Evaporator Temperature Sensor
Air Conditioning (A/C) System (12.03) Climate Control (12.00) Installation Removal 1. Install the power transistor and connect the wiring 1. Disconnect the vehicle battery. harness plug. 2. Remove the A/C unit (Refer to ’A/C Unit’, page 12-3- 2. Install the glove box. 11).
Page 414: Trinary Switch
Air Conditioning (A/C) System (12.03) Climate Control (12.00) Trinary Switch Expansion Valve Repair Operation Time (ROT) Repair Operation Time (ROT) Item Code Item Code A/C Trinary Switch Renew A/C Expansion Valve Renew Removal Removal 1. Disconnect the vehicle battery. 1. Disconnect the vehicle battery. 2.
Page 415 Air Conditioning (A/C) System (12.03) Climate Control (12.00) Installation Install new ‘O’ rings. Apply compressor oil to the ‘O’-ring joints. 1. Install the expansion valve to the A/C unit body. 2. Install the A/C pipes to the expansion valve. 3. Install the A/C pipes clamp. 4.
Page 416: Troubleshooting
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 417 Air Conditioning (A/C) System (12.03) Climate Control (12.00) Symptom(6) Description Possible Cause Air from vents not cold enough. Magnetic clutch operates but • Drive belt fault A/C system malfunctions. • Fault in blower unit or condenser • Fault in Receiver / Drier or expansion valve (valve closes too much) •...
Page 418 Air Conditioning (A/C) System (12.03) Climate Control (12.00) 12-3-24 Workshop Manual Issue 3 October 2007...
Page 419: 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 Message Centre Left ..........1-4 Gear Position Indicator Display (GPID)....1-4 Message Centre Right .......... 1-4 Maintenance ............
Page 420: Instrument Cluster (13.01)
Instrument Cluster (13.01) Information, Gauge and Warning (13.00) Information, Gauge and Warning (13.00) Driver Information Module (DIM) (13.01) Description GPID Fuel Odometer Message Message Coolant Display Gauge Centre Centre Counter Temperature Left Right Gauge The Driver Information module contains the necessary electronic control units and memories to control, process and present all necessary vehicle information to the driver.
Page 421: 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.
Page 422: Dim Display Layout
Instrument Cluster (13.01) Information, Gauge and Warning (13.00) DIM Display layout Manual Transmission On a manual transmisssion vehicle the GPID display informs The DIM contains two displays, which are used to inform the the driver when the current gear has reached it’s upper rev. driver about the vehicles status.
Page 423: Maintenance
Instrument Cluster (13.01) Information, Gauge and Warning (13.00) Maintenance 4. Remove the screws (x4) that secure the DIM. Withdraw the DIM to the extent of the wiring harness. Driver Information Module (DIM) Ensure the spacers are retained. Repair Operation Time (ROT) Item Code Driver Information Module (DIM)
Page 424: Installation
Instrument Cluster (13.01) Information, Gauge and Warning (13.00) Installation 1. Place the DIM to it’s mounting point. Connect the wiring harness plug. 2. Install the DIM (screws x4). 3. Install the DIM bezel (screws x5). Ensure that the DIM finishers install on the inside of the cluster bezel.
Page 425 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............1-5 Maintenance ............1-5 Battery ..............1-5 Removal.............. 1-5 Installation ............1-5 Alternator and Regulator System (14.02) ....14-2-1 Description .............
Page 426: 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 drivers 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 427: Charging Circuit
Battery System (14.01) Power Supply (14.00) Charging Circuit Alternator / Generator Secondary PCM C0637-38G UW,0.5 C0226-1 ALTMON ALTMON C1893-1 Switch-Battery Disconnect Engine Bay Dirty Feed Terminal-Jump Start BDS Power Power BDS Power C0046-A SPL - TPIECE C2607-1 C2307-1 B,50.0 B,50.0 B,50.0 B,50.0 C0046-B...
Page 428 Battery System (14.01) Power Supply (14.00) R,50.0 B,50.0 14-1-4 Workshop Manual Issue 3, October 2007...
Page 429: Specifications
Battery System (14.01) Power Supply (14.00) Specifications 5. Remove the battery clamp. Disconnect battery vent tube and pull the battery from the compartment. Warning Torque Figures The vehicle battery is heavy and access to the battery is Description lb. / ft. restricted.
Page 430 Battery System (14.01) Power Supply (14.00) 14-1-6 Workshop Manual Issue 3, October 2007...
Page 431: 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 Maintenance The alternator installed to this vehicle is a Denso, SC2, 150 Alternator amp rating, with a 14.4 volt regulator. Repair Operation Time (ROT) Item Code Alternator Renew...
Page 432: Installation
Alternator and Regulator System (14.02) Power Supply (14.00) Installation 7. Remove bolts / washers (x3). Withdraw the alternator complete with the cooling shield. 1. Place the alternator complete with the cooling shield to mountings. Insert bolt (1) as cooling shield is placed to alternator. Remove Bolts 2.
Page 433 Vehicle Entertainment (15.00) Contents Audio System (15.01)...........15-1-2 Issue 3, October 2007 Workshop Manual 15-1-1...
Page 434: Vehicle Entertainment (15.00)
Audio System (15.01) Vehicle Entertainment (15.00) Vehicle Entertainment (15.00) Audio System (15.01) Refer to manufactures literature 15-1-2 Workshop Manual Issue 3, October 2007...
Page 435 Vacuum System (16.00) Contents Vacuum Distribution (16.01).......16-1-2 Description ............. 1-2 Issue 3, October 2007 Workshop Manual 16-1-1...
Page 436: Vacuum Distribution (16.00)
Vacuum Distrbution (16.01) Vacuum System (16.00) Vacuum System (16.00) Vacuum Distribution (16.01) Description 16-1-2 Workshop Manual Issue 3, October 2007...
Page 437 Lighting (17.00) Contents Front Lights (17.01) ..........17-1-2 Specifications............1-2 Maintenance ............1-2 Headlamp Unit ............1-2 Headlight Alignment ..........1-3 Continental Conversion.......... 1-3 Bulb Renewal ............1-4 Side Repeater Lamp Unit - Remove and Install and Replace Bulb ..........1-6 Side Marker Unit Bulb ...........
Page 438: Lighting (17.00)
Front Lights (17.01) Lighting (17.00) Lighting (17.00) Front Lights (17.01) 5. Disconnect the headlamp unit wiring harness plugs (x3) Specifications Bulbs Type Type Rating (European) (Federal) Headlight dipped beam Headlight main beam 65W Front Indicators 27W / PY27W 3457 AK Front Position Lamp W5W (Blue) W5W (Blue) Side Repeater...
Page 439: Headlight Alignment
Front Lights (17.01) Lighting (17.00) Headlight Alignment 5. Switch the ignition to position ‘II’ then back to position ‘0’ to ensure that the headlight units are at their set Headlight alignment should be carried out with vehicle at position. design weight, i.e., 6.
Page 440: Bulb Renewal
Front Lights (17.01) Lighting (17.00) Bulb Renewal 5. Locate the conversion switch and move up / down until a positive ‘click’ is heard. LH Headlamp Unit Gain access to the headlight unit by first removing the access panel in the road wheel arch liner. RH Headlamp Unit Dipped Beam Repair Operation Time (ROT)
Page 441 Front Lights (17.01) Lighting (17.00) Indicator and Side Light 3. Disconnect wiring harness plug. Remove the spring clip and withdraw the bulb unit. Repair Operation Time (ROT) Item Code Indicator Bulb Renew 17.01.EB 17.01.FB Side Bulb Renew 17.01.JB 17.01.KB 1. Rotate the bulb holder a quarter turn anti-clockwise and withdraw.
Page 442: Side Repeater Lamp Unit - Remove And Install And Replace Bulb
Front Lights (17.01) Lighting (17.00) Side Repeater Lamp Unit - Remove and 5. Install the two M6 Torx head screws that attach the wheelarch liner. Install and Replace Bulb 6. Lower the vehicle. Repair Operation Time (ROT) Side Marker Unit Bulb Item Code Side Repeater Lamp Unit - Remove and...
Page 443 Front Lights (17.01) Lighting (17.00) 5. Disconnect the electrical connector at the rear of the side marker unit and remove the assembly. 6. Connect the electrical connector to a new side marker unit and install. 7. Front Side Marker Unit Only. Install the road wheel arch liner.
Page 444 Front Lights (17.01) Lighting (17.00) 17-1-8 Workshop Manual Issue 4, November 2008...
Page 445: Interior Lighting (17.02)
Interior Lighting (17.02) Lighting (17.00) Lighting (17.00) Interior Lighting (17.02) Rear Quarter Lamp Specifications Bulbs Rating Type Reading lamp Rear occupant lamp Boot lamp Maintenance Interior Light Bulb Renew Repair Operation Time (ROT) Item Code Interior Bulb Renew 17.02.AB 1. Taking care to protect the trim panel, lever the lamp unit from the trim panel.
Page 446 Interior Lighting (17.02) Lighting (17.00) 17-2-2 Workshop Manual Issue 3 October 2007...
Page 447: Rear Lights (17.03)
Rear Lights (17.03) Lighting (17.00) Lighting (17.00) Rear Lights (17.03) 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. Specifications Bulbs Rating Type Rear light cluster Rear side marker...
Page 448 Rear Lights (17.03) Lighting (17.00) 17-3-2 Workshop Manual Issue 3 October 2007...
Page 449: Lighting Mechanisms (17.04)
Lighting Mechanisms (17.04) Lighting (17.00) Lighting (17.00) Lighting Mechanisms (17.04) Headlamp Levelling Maintenance Front Level Sensor Repair Operation Time (ROT) Item Code Front Level Sensor Renew 17.04.BB Removal 1. Disconnect the vehicle ride height sensor from the lower suspension arm. 2.
Page 450: Rear Level Sensor
Lighting Mechanisms (17.04) Lighting (17.00) Rear Level Sensor Repair Operation Time (ROT) Item Code Rear Level Sensor Renew 17.04.CB Removal 1. Disconnect the vehicle ride height sensor from the upper suspension arm. 2. Remove the ride height sensor from the subframe. Installation 1.
Page 451: Electric Distribution/Electronic Control (18.00)
Electric Distribution/Electronic Control (18.00) Contents Wiring and Circuit Protection (18.01) ....18-1-2 Fuse Boxes .............. 1-2 Fuse Listings............1-2 Engine Bay Fuse / Relay Box........ 1-2 Central Electronics Module Fusebox....1-3 ................1-4 Stand Alone Fuses..........1-4 Boot Fusebox............1-4 How to Read the Circuits........1-4 Wires..............
Page 452: Wiring And Circuit Protection (18.01)
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: RH drive shown.
Page 453 Wiring and Circuit Protection (18.01) Electric Distribution/Electronic Control (18.00) Fuse Rating Function Fuse Rating Function Module - ABS, Key Reader and Steering Front windscreen relay and wash pump angle sensors Airbag module Spare Spare Alternator battery sensing Diagnostic connectors / Centre stack Heated front screen switches Wiper (slow)
Page 454: Stand Alone Fuses
Wiring and Circuit Protection (18.01) Electric Distribution/Electronic Control (18.00) Relay Rating Function Fuel pump driver module (7-12 (Bank B)) Stand Alone Fuses Tracker (If installed) Fuse Rating Function Fuel pump driver module (1-6 (Bank A)) Cabin Fuse box supply Cabin Fuse box supply Cansiter vent valve Blank Exhaust bypass valve and vacum pump...
Page 455: Twisted Wires
Wiring and Circuit Protection (18.01) Electric Distribution/Electronic Control (18.00) Controller Area Network (CAN) Twisted Wires The ‘figure of 8’ shown on circuits as below denotes a Controller Area Network (CAN) is the wiring between twisted wire and shows the wires that are twisted together. intelligent modules of the vehicle.
Page 456: Connectors
Wiring and Circuit Protection (18.01) Electric Distribution/Electronic Control (18.00) Connectors Media Oriented System Transport (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 457: Splices
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 458: Relays
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 459: Resistors
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 460: Motor
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 461 Wiring and Circuit Protection (18.01) Electric Distribution/Electronic Control (18.00) Component Identification Component Connector Circuit Page Cabin-Boot Inline 4 C0109 Component Connector Circuit Page Cabin-Boot Inline 7 C0607 Airbag-Driver C0257 Cabin-Boot Inline 8 C0608 Airbag-Passenger1 C0251 Cabin-Boot MOST Connector C0420 Airbag-Passenger2 C0261 Cabin-Centre Stack Inline 1 C0083...
Page 462 Wiring and Circuit Protection (18.01) Electric Distribution/Electronic Control (18.00) Component Connector Circuit Page Component Connector Circuit Page Driver Seat-Conn3 C0751 2, 61A Earth Eyelet-ECU B Caseground C2650 Driver Seat-Conn4 C0255 15, 61 Earth Eyelet-ECU B C0558 Powerground Drivers Door Module Conn 1 C0336 22, 23, 26, Earth Eyelet-ECU B...
Page 463 Wiring and Circuit Protection (18.01) Electric Distribution/Electronic Control (18.00) Component Connector Circuit Page Component Connector Circuit Page Earth Eyelet-Passenger Door C2601 22, 24, 27, ECU B (T-Trans) C0637 Eyelet-Battery Feed to Battery C2175 Conditioner Earth Eyelet-Passenger Seat C0811 Eyelet-Boot Fusebox Battery C2609 Earth Eyelet-Passenger Seat C2569...
Page 464 Wiring and Circuit Protection (18.01) Electric Distribution/Electronic Control (18.00) Component Connector Circuit Page Component Connector Circuit Page Heated Front Screen-RH C0246 Module-Aircon-Conn A C0791 Heated Rear Window (Feed) C0381 Module-Aircon-Conn B C0792 Heated Rear Window (Gnd) C0382 Module-Amplifier (AUD2) C2589 45, 46 Horn C0003...
Page 465 Wiring and Circuit Protection (18.01) Electric Distribution/Electronic Control (18.00) Component Connector Circuit Page Component Connector Circuit Page Multi Media Module Display C2516 Sensor-Catalyst Monitor-Rear C0644 (Power) Sensor-Crank Position A C0168 Multi Media Module Display C2515 Sensor-Crank Position B C0170 (Screen) Sensor-Engine Coolant Level C0147 Passenger Door Module Conn 1...
Page 466 Wiring and Circuit Protection (18.01) Electric Distribution/Electronic Control (18.00) Component Connector Circuit Page Component Connector Circuit Page Sounder-PDC Rear C0405 Switchpack-Seat-Manual 3 C2801 Speaker-Dual-Front Centre C0369 Switch-Park C2736 Speaker-Dual-Front Left C0340 Switch-PDC Disable C1541 Speaker-Dual-Front Right C0339 Switch-Rear Fog Lamps C0064 10, 37 Speaker-Rear Left...
Page 467: Maintenance
Wiring and Circuit Protection (18.01) Electric Distribution/Electronic Control (18.00) Maintenance 5. Install earth connection onto the fuel tank stud. 6. Install and tighten attachmenty nut for the earth Fuel Tank Harness - Remove and Install connection. 7. Install the fuel tank and cannister assembly (Refer to Repair Operation Time (ROT) ’Fuel Tank - Remove and Install’, page 10-1-11).
Page 468: Circuit Diagrams
Wiring and Circuit Protection (18.01) Electric Distribution/Electronic Control (18.00) Circuit Diagrams 18-1-18 Workshop Manual Issue 4, November 2007...
Page 482 OU,0.5...
Page 483 BY,0.5 BY,0.5...
Page 485 C2409-1...
Page 486 B,0.5...
Page 488 B,0.5 B,0.5...
Page 490 U,0.5...
Page 491 BK,2.5 Y,0.5 PROFET...
Page 494 RB,05 RN,05 120 Ohms...
Page 497 120 Ohms 120 Ohms 120 Ohms 120 Ohms...
Page 503 BY,0.5 BU,0.5...
Page 514 B,4.0 B,4.0 PROFET...
Page 516 B,2.0 B,0.5 B,1.0 B,1.0...
Page 517 B,0.5 C0384-6 B,0.5 B,1.0 B,0.5 B,0.5 BY,0.5 BY,0.5 OU,0.5...
Page 521 B,0.5...
Page 533 B,0.5 C0467-1 B,0.5 B,0.5 C2246-12 C2246-4 C2246-6 C2246-2 C2246-1 C2246-8 C2246-9 C2246-7 C2246-10 C2246-3 C2246-5 OY,0.75...
Page 537 U,0.5...
Page 538 R,50.0 B,50.0...
Page 539 B,50.0 B,50.0...
Page 544 U,0.5...
Page 549 GY,0.5...
Page 550 Coupe Convertible...
Page 551 BU,0.5 U,0.5...
Page 554 B,1.5 B,1.5 C2409-29...
Page 555 FO,FO FO,FO FO,FO FO,FO FO,FO...
Page 556 FO,FO FO,FO FO,FO FO,FO FO,FO...
Page 557 PCMs...
Page 559: Vehicle Control System (18.08)
Vehicle Control Modules (18.08) Electric Distribution/Electronic Control (18.00) Electric Distribution/Electronic Control (18.00) Vehicle Control System (18.08) Module Configuration Customer Configuration Principles of Operation There are certain modules / functions that the customer may or may not want reconfigured or enabled. Some of these All configurable modules are packaged in a kit which preferences are accessed through the ‘in-car’...
Page 560 Vehicle Control Modules (18.08) Electric Distribution/Electronic Control (18.00) Module Locations (RHD) 18-8-2 Workshop Manual Issue 3, October 2007...
Page 561 Vehicle Control Modules (18.08) Electric Distribution/Electronic Control (18.00) Issue 3, October 2007 Workshop Manual 18-8-3...
Page 562 Vehicle Control Modules (18.08) Electric Distribution/Electronic Control (18.00) Module Locations (LHD) 18-8-4 Workshop Manual Issue 3, October 2007...
Page 563 Vehicle Control Modules (18.08) Electric Distribution/Electronic Control (18.00) Issue 3, October 2007 Workshop Manual 18-8-5...
Page 564 Vehicle Control Modules (18.08) Electric Distribution/Electronic Control (18.00) 18-8-6 Workshop Manual Issue 3, October 2007...
Page 565: 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 566: 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 567: Functional Description
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 568: Remote Transmitter
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 Description be used for controlling the system functions. The remote transmitter come in packs of two. Each IPATS (immobilisation system) is responsible for enabling / transmitter is associated with a series of numbers, which are disabling engine functionality.
Page 569: Key Programming
Active Anti-Theft System (19.01) Electronic Features (19.00) Key Programming Alarm Siren Assembly - Remove and Install Internet access required Repair Operation Time (ROT) All vehicle keys are required to perform key programming. Item Code Using AMDS. Alarm Siren Assembly - Remove and 19.01.CA 1.
Page 570 Active Anti-Theft System (19.01) Electronic Features (19.00) 19-1-6 Workshop Manual Issue 7, September 2011...
Page 571: Navigation (19.07)
Navigation (19.07) Electronic Features (19.00) Electronic Features (19.00) Navigation (19.07) 11. Manually move the navigation display screen into the open position. Maintenance Mechanism for the Navigation Display Screen - Remove and Install (12MY onward) Repair Operation Time (ROT) Item Code Mechanism for the Navigation Display 19.07.CA Screen - Remove and Install (12MY...
Page 572 Navigation (19.07) Electronic Features (19.00) 14. Remove the two screws that attach the holder for the 17. Remove the holder for the navigation display screen. navigation display screen to the mechanism for the navigation display screen. 18. Remove the navigation display screen. 15.
Page 573 Navigation (19.07) Electronic Features (19.00) Install 20. Remove the veneer bezel door. 1. Install the mechanism for the navigation display screen. 21. Remove the four screws that attach the mechanism for the navigation display screen to the veneer bezel. 2. Install, but do not fully tighten, the four screws that attach the mechanism for the navigation display screen to the veneer bezel.
Page 574 Navigation (19.07) Electronic Features (19.00) 4. Install and tighten the four screws that attach the veneer 7. Install the holder for the navigation display screen to the bezel door for the navigation display screen to the two clips that attach it to the mechanism for the mechanism for the navigation display screen.
Page 575 Navigation (19.07) Electronic Features (19.00) 10. Connect the electrical connector to the navigation 13. Install the wiring harness for the navigation display display screen. screen to the clip that attaches it to the mechanism for the navigation display screen. 11. Install and new cable tie that attaches the wiring harness to the navigation display screen.
Page 576: Navigation Display Screen - Remove And Install
Navigation (19.07) Electronic Features (19.00) 16. Tighten the four screws that attach the mechanism for 3. Release the wiring harness for the navigation display the navigation display screen to the veneer bezel. screen from the clip that attaches it to the mechanism for the navigation display screen.
Page 577 Navigation (19.07) Electronic Features (19.00) 6. Disconnect the electrical connector from the navigation 9. Release the holder for the navigation display screen display screen. from the two clips that attach it to the mechanism for the navigation display screen. 7. Remove the two screws that attach the holder for the navigation display screen to the mechanism for the 10.
Page 578 Navigation (19.07) Electronic Features (19.00) Install 4. Install the holder for the navigation display screen to the mechanism for the navigation display screen. 1. Install the navigation display screen. 5. Install and tighten the two screws that attach the holder 2.
Page 579 Navigation (19.07) Electronic Features (19.00) 7. Install and new cable tie that attaches the wiring harness 10. Install the electrical connector to the clip that attaches it to the navigation display screen. to the mechanism for the navigation display screen. 8.
Page 580 Navigation (19.07) Electronic Features (19.00) 19-7-10 Workshop Manual Issue 7, September 2011...
Page 581: Appendix & Glossary
Appendix & Glossary Contents Diagnostic Ports ..........20-1-2 Fluids / Capacities..........20-1-2 Terms..............20-1-3 Special Tools - Pictorial Index ......20-1-3 Specialist Tool Operation ........20-1-8 Engine Support Brackets (43-27940) ....20-1-8 PowerTrain Trolleys (43-27981) ......20-1-8 Front Mounts ............20-1-8 Rear Mounts .............20-1-9 PowerTrain Trolleys Brace Bars (43-28161) ............20-1-9 Ball Joint Splitter (43-26738) ......20-1-10 Track Rod Ends ..........20-1-10...
Page 582: Diagnostic Ports
Manual gearbox oil / Castrol BOT270A Final drive Brake / Clutch fluid Castrol React Performance DOT4 Power steering fluid Pentosin CHF 11S (Current production) Texaco Cold Climate (DB9 up to A12418 - EXAMINE THE LABEL ON THE PAS RESERVOIR) A/C refrigerant HFC134A. Fuel 95 RON Unleaded (Min.) or 98...
Page 583: Terms
Special Tools - Pictorial Index Appendix & Glossary Terms Part No. / Description 43-26738 (Ball Joint Splitter) Frequently used alternative names or spellings for vehicle components mentioned in this Workshop Manual. UK English US English Bonnet Hood Boot Trunk Brake Disc Rotor Handbrake Parking Brake...
Page 584 Special Tools - Pictorial Index Appendix & Glossary Part No. / Description Part No. / Description 43-27930 (Rear Subframe Bush Installer) 43-27831 (Crankshaft Rear Oil Seal Slinger Install) Image to Follow 43-27411 (Crankshaft Rear Oil Seal Install) 43-27822 (Brake Hose Install) Image to Follow 43-27412 (Crankshaft Front Oil Seal Install) 43-27933 (Handbrake Cable Removal)
Page 585 Special Tools - Pictorial Index Appendix & Glossary Part No. / Description Part No. / Description 43-27974(Camshaft Set) 43-27987 (Trolley Brace Bars) 43-27873 (Crankshaft Holding) 43-27981 (Multi-purpose Trolley) x2 43-27944 (Timing Chain Tensioner Pins) 43-27985 (Rear Subframe Trolley Adaptors) 43-27945 (Engine Support Adaptor) 43-27986 (Engine/Subframe Trolley Adaptors) Issue 7, September 2011 20-1-5...
Page 586 Special Tools - Pictorial Index Appendix & Glossary Part No. / Description Part No. / Description 43-27946 (Engine Lifting Brackets) 43-28005 (Filler Neck Disconnect Tool) 43-28006 (Fuel Tank Drainage Adaptor) 43-27947 (Engine Mount Top Nut Adaptor) 310-140 (Fuel Pump Install / Remove) 43-27996 (Transaxle Seal Instal) 43-28002 (Fuel Pipe Disconnect Tool) 43-28009 (Quick Disconnect Tool)
Page 587 Special Tools - Pictorial Index Appendix & Glossary Part No. / Description Part No. / Description 43-28015 (Quick Disconnect Tool) 43-28089 (Trim Removal) 43-28090 (IP Alignment Pins) 43-28052 (Oxygen Sensor Diagnostic Lead) 43-28095 (Door Service Trolley) 501-073A (Airbag Simulators) 43-28079 (Side Airbag and Pretensioner simulators) 43-28092 (Front Veneer Removal) Issue 7, September 2011 20-1-7...
Page 588: Specialist Tool Operation
Specialist Tool Operation Appendix & Glossary Specialist Tool Operation Part No. / Description 43-28096 (IP Removal) To assist the technician in the operation of some of the specialist tools available for this vehicle, listed here are specialist tool operating procedures. Engine Support Brackets (43-27940) PowerTrain Trolleys (43-27981) Images of where to locate the powertrain trolleys to the rear...
Page 589: Rear Mounts
Specialist Tool Operation Appendix & Glossary PowerTrain Trolleys Brace Bars Rear Mounts (43-27987) Issue 7, September 2011 20-1-9...
Page 590: Ball Joint Splitter (43-26738)
Specialist Tool Operation Appendix & Glossary Ball Joint Splitter (43-26738) Brake Hose Check (43-27822) Track Rod Ends Front Brake Caliper To get access to the vertical link lower ball joint. CAUTION 1. For each affected wheel station, loosen the road wheel MAKE SURE THAT THE ALIGNMENT LINE ON THE nuts ¼...
Page 591: Crankshaft Rear Oil Seal Remove (43-27831)
Specialist Tool Operation Appendix & Glossary Crankshaft Rear Oil Seal Remove (43-27831) CAUTION THROUGHOUT THIS PROCEDURE IT IS ESSENTIAL THAT ALL PARTS REMAIN CLEAN, FREE OF DIRT, GREASE AND DEBRIS. 1. Using the sleeved punch (supplied with the new oil seal kit), pierce three equally spaced holes in the oil seal slinger.
Page 592: Crankshaft Rear Oil Seal Installer (43-27411)
Specialist Tool Operation Appendix & Glossary 9. Screw the sleeved screw (supplied with the new oil seal 3. Wipe the lip of the new oil seal with clean engine oil. kit) into the pierced hole enough to attach to the 4.
Page 593 Specialist Tool Operation Appendix & Glossary 7. Using the oil seal slinger install tool repeat from step two to install the oil seal slinger. The oil seal slinger installs one way only on the oil seal slinger install tool. Issue 7, September 2011 20-1-13...
Page 594: Torque Figures
Specialist Tool Operation Appendix & Glossary Torque Figures General Torque Figures Nom. Dia. Applied Torque (Nm) 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 +/-...
Page 595: Torque Conversion Tables
Torque Conversion Tables Appendix & Glossary 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 18.44 19.18 19.91...
Page 596 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 597 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 598 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 599 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...
Page 600 Torque Conversion Tables Appendix & Glossary 20-1-20 Workshop Manual Issue 7, September 2011...

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