2005-2010 ASTON MARTIN DB9 Workshop / Repair / Service Manual

Workshop Manual Issue 2 DB9

Aston Martin Lagonda Limited Banbury Road, Gaydon, WARWICK, Warwickshire, England, MK16 9AN Telephone: (01926) 644700 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. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted, in any form, electronic, mechanical, photocopying, recording or other means without prior written permission from Aston Martin Lagonda Limited. The manufacturer reserves the right to vary specifications without notice in accordance with its policy of continual product improvement. Produced by the Technical Publications Department Aston Martin Lagonda Limited Issue 2 - February 2005 Part No. 4G43-43-10032

Issue 2 February 2005 Workshop Manual I-I-III DB9 Workshop Manual Contents Introduction Welcome ............................................................... i-i-iv Safety Precautions ................................................... i-i-v Lifting and Jacking ................................................. i-i-vii Vehicle Recovery ..................................................i-i-viii Vehicle Identification Number ............................... i-i-ix Body System (01.00) Body Structure (01.01) .......................................... 1-1-3 Front End System (01.02) ...................................... 1-2-1 Body Closures (01.03) ........................................... 1-3-1 Interior Trim (01.05) ............................................. 1-4-1 Exterior Trim (01.08) ............................................. 1-5-1 Mirrors (01.09) ...................................................... 1-6-1 Seating (01.10) ...................................................... 1-7-1 Glass, Frame and Mechanism (01.11) .................... 1-8-1 Instrument Panel (IP) (01.12) ................................. 1-9-1 Handles and Lock Mechanisms (01.14) ............... 1-10-1 Wipers and Washer System (01.16) ..................... 1-11-1 Bumpers (01.19) ................................................. 1-12-1 Restraining Devices (01.20) ................................. 1-13-1 Frame and Mounting (02.00) Subframes (02.03) ................................................. 2-1-2 Engine System (03.00) Engine Assembly (03.00) ....................................... 3-1-3 Engine Structure (03.01) ........................................ 3-2-1 Lubrication System (03.02) .................................... 3-3-1 Cooling System (03.03) ......................................... 3-4-1 Fuel Charging System (03.04) ................................ 3-5-1 Accessory Drive System (03.05) ............................. 3-6-1 Engine Cranking System (03.06) ............................ 3-7-1 Ignition System (03.07) ......................................... 3-8-1 Emission Control (03.08) ....................................... 3-9-1 Valve Train (03.09) ............................................. 3-10-1 Engine Sealing (03.10) ......................................... 3-11-1 Power Conversion (03.11) ................................... 3-12-1 Air Charging (03.12) ............................................ 3-13-1 Evaporative Emissions (03.13) ............................. 3-14-1 Engine Management System (03.14) .................... 3-15-1 Throttle Control (03.16) ...................................... 3-16-1 Suspension (04.00) Road Wheel Alignment (04.00) ............................. 4-1-2 Front Suspension (04.01)....................................... 4-2-1 Rear Suspension (04.02)........................................ 4-3-1 Road Wheels and Tyres (04.04) ............................ 4-4-1 Driveline (05.00) Driveshaft (05.01) ................................................. 5-1-2 Rear Drive System (05.02) .................................... 5-2-1 Halfshafts (05.05) .................................................. 5-3-1 Brake System (06.00) Description ........................................................... 6-1-2 Front Disc Brake (06.03) ....................................... 6-2-1 Rear Disc Brakes (06.04) ....................................... 6-3-1 Hand Brake (06.05) .............................................. 6-4-1 Brake Actuation System (06.06) ............................ 6-5-1 Power Brake System (06.09) ................................. 6-6-1 Transmission (07.00) Automatic Transmission (07.01) ............................ 7-1-2 Transmission Cooling (07.02) ................................ 7-2-1 Manual Transmission (07.03) ................................ 7-3-1 Automatic Control System (07.05) ......................... 7-4-1 Clutch (08.00) Clutch Controls (08.02) ......................................... 8-2-1 Exhaust (09.00) Exhaust Overview ................................................. 9-1-2 Silencer Assembly (09.01) ..................................... 9-1-3 Pipes and Supports (09.03) ................................... 9-2-1 Fuel (10.00) Fuel Tank and Lines (10.01) ................................ 10-1-2 Steering (11.00) Steering Gear (11.01) .......................................... 11-1-2 Power Steering (11.02)........................................ 11-2-1 Steering Column (11.04) ..................................... 11-3-1 Steering Column Switches (11.05) ....................... 11-4-1 Steering Wheel (11.06) ....................................... 11-5-1 Climate Control (12.00) Body Ventilation system (12.01) .......................... 12-1-3 Heater System (12.02) ........................................ 12-2-1 Air Conditioning (A/C) System (12.03) ................. 12-3-1 A/C Control System (12.04) ................................. 12-4-1 Information, Gauge and Warning (13.00) Instrument Cluster (13.01) .................................. 13-1-2 Power Supply (14.00) Battery System (14.01) ........................................ 14-1-2 Alternator and Regulator System (14.02) ............. 14-2-1

I-I-IV Workshop Manual Issue 2 February 2005 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) ................. 18-1-2 Vehicle Control System (18.08) .......................... 18-2-1 Electronic Features (19.00) Active Anti-Theft System (19.01) ......................... 19-1-2 Appendix & Glossary Diagnostic Ports................................................... 20-1-2 Fluids/Capacities.................................................. 20-1-3 Abbreviations ...................................................... 20-1-3 Terms .................................................................. 20-1-3 Special Tools - Pictorial Index .............................. 20-1-4 Specialist Tool Operation .................................... 20-1-8 Maintenance Schedules ..................................... 20-1-11 Torque Figures .................................................. 20-1-14 Torque Conversion Tables ................................. 20-1-31

Issue 2 February 2005 Workshop Manual I-I-V 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 ........................... I-VII Electrical Equipment ............................................. I-VII Exhaust Fumes ..................................................... I-VIII Fire Precautions ................................................... I-VIII Tools and Equipment........................................... I-VIII Used Engine Oil ................................................... I-VIII Health Protection Precautions ............................. I-VIII Environmental Protection .................................... I-VIII Lifting and Jacking ................................................. I-I-IX Safety ..................................................................... I-IX Jacking Points ........................................................ I-IX Stands ................................................................. I-IX Workshop Hoist..................................................... I-IX Vehicle Recovery .................................................... I-I-X General .................................................................... I-X Transporting ............................................................ I-X Suspended Towing ................................................. I-X Front Suspended Tow........................................... I-X Rear Suspended Tow ............................................ I-X Towing an Automatic Vehicle ................................. I-X Towing Regulations ................................................. I-X Towing by Another Vehicle ..................................... I-X Push-start ................................................................ I-X Identification Numbers ......................................... I-I-XI Vehicle Identification Number (VIN) ...................... I-XI VIN Number Location............................................ I-XI Engine Number..................................................... I-XII Gearbox Number.................................................. I-XII Automatic Gearbox............................................... I-XII Manual Gearbox ................................................... I-XII

Welcome Introduction I-I-VI Workshop Manual Issue 2 February 2005 Introduction Welcome This Workshop Manual is part of a suite of technical manuals provided for DB9. Other technical manuals include: • Parts manual • OBDII Diagnostic manual • Man hour schedules Chapters The DB9 suite of manuals incorporate a new chapter structure. Each chapter in this workshop manual is associated with a 4 digit number, i.e. Transmission (07.00). Each chapter is then further broken into sections, i.e. Automatic Transmission (07.01). Chapter Navigation Example 1: Previous workshop manuals would have Steering and Suspension together in one chapter. The new structure now places Steering and Suspension into their own chapters. Road wheels are also now included in Suspension. Example 2: Fuel, emissions and exhaust is now in three different chapters. Fuel has its own chapter and includes all fuel aspects up to the fuel rails (Fuel rails and fuel injection now come under Engine System). Exhaust, not including manifolds, has its own chapter and Emissions now come under the Engine system. When required references are made out to other chapters. Numbering Chapters and sections within chapters are numbered using the system detailed above. All technical manuals for this vehicle use the same numbering system. When carrying out a procedure, the relevant parts illustration and spare parts list can be found using the same numbering system. To avoid excessive repetition, each procedure is fully detailed once in its appropriate chapter. In any other location where this procedure is required, it is referenced by its title and chapter / page number. Special Tools Where special service tools are required to perform an operation, the tool number is recorded at the point of use within the procedure. Where the operation of a special service tool is complicated or not obvious, refer to the Appendix and Glossary for detailed operation procedures. A pictorial list of special service tools available for this vehicle can also be found in the Appendix and Glossary. Location References References to left, right, front or rear of the vehicle or of a component are referenced from sitting in the drivers seat facing forward. Any such references to assemblies removed from the vehicle are to the normal orientation of the assembly when installed in the vehicle. Warnings, Cautions and Notes The following Warnings, Cautions and Notes are used within this workshop manual to call your attention to specific types of information. Warnings Cautions Notes Repairs and Replacements Where replacement parts are required, it is essential that only genuine Aston Martin parts are used. Your attention is drawn to the following points concerning repairs and the fitting of genuine Aston Martin parts and accessories: • Safety features embodied in the vehicle may be impaired if other than genuine Aston Martin parts are installed. In certain territories, legislation prohibits the installation of parts which are not produced to the manufacturers specification • Adhere to torque wrench settings given in this manual • Locking devices, where specified, must be installed. If the efficiency of a locking device is impaired during removal, it must be renewed • The vehicle warranty may be invalidated by the installation of other than genuine Aston Martin parts 03. 02. System, i.e. Engine system Subsystem, i.e. Engine lubrication system Warning Identifies procedures which must be followed precisely to help avoid the risk of personal injury. Caution Provided to indicate procedures which must be followed precisely to reduce the possibility of damage to the vehicle. Provided to indicate procedures which will help to avoid difficulties in the operation of the vehicle.

Safety Precautions Introduction Issue 2 February 2005 Workshop Manual I-I-VII 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. Statutory requirements governing all aspects of health and safety at work including directives for the proper use of materials and equipment must be implemented. The following headings highlight particular safety precautions which should be observed (The list is not intended to be exhaustive). Battery Disconnection Where a procedure requires the vehicle battery to be physically disconnected (disconnect the vehicle battery earth (Negative) lead), the following items will have to be reset or re-learnt on connection: • Seats memory • Radio pre-sets • DTCs will be lost Air Conditioning (A/C) System Do not break into the A/C refrigeration system until the refrigerant has been evacuated using the procedure detailed in this manual. Do not disconnect any A/C refrigerant system pipes unless trained and instructed to do so. The refrigerant used can cause blindness if allowed to contact your eyes. Chemical Handling and Storage Chemicals used in the servicing of motor vehicles include acids, adhesives, antifreeze, brake fluids, coolants, grease, oil, paint, resin and solvents. Exposure to certain chemicals through direct contact or inhalation can be fatal. Potential hazards may also be present through the incorrect use, storage and handling of chemicals causing a fire risk. Electrical Equipment Warning Strictly adhere to handling and safety information found on containers and labels. Warning Do not store chemicals in unlabelled or incorrectly labelled containers. Warning Containers used for storing chemicals should not be left open; there is a risk of spilling, or evaporation of fumes which may be inflammable or toxic. Warning Do not mix chemicals unless instructed to do so, following manufacturers guidelines. Warning Do not inhale chemical materials to determine identity, they may be toxic. Warning Do not use petrol, kerosene, diesel fuel, gas oil, thinners or solvents for washing skin. Warning Chemicals based on solvents such as paint should not be sprayed in a confined space; work areas used for such operations should be well ventilated and fume extraction equipment should be utilised. Warning Containers whose capacity is over 25 litres (5 gallons) require a bund wall in order to contain spillages. Warning Avoid splashing the skin, eyes and clothing. Warning Ensure that adequate ventilation is provided when volatile de-greasing agents are being used. Warning Clean chemicals from the skin and clothing as soon as possible after soiling. Warning Wear protective clothing such as goggles, non porous gloves and apron when handling battery acid and other corrosive and toxic substances. Warning Do not smoke in the vicinity of volatile de-greasing agents. Warning Fume extraction equipment must be in operation when solvents are used e.g. trichloroethane, white spirit, SBP3, methylene chloride, perchloroethylene. Warning Ensure that electrical equipment is in safe working order before use. Warning Inspect power leads of all mains electrical equipment for damage and security, and check that it is properly earthed. Warning Ensure that electrical equipment is protected by a fuse of the correct current rating. Warning Disconnect the battery before commencing repair operations to the electrical system, fuel system and engine or when working beneath the vehicle.

Safety Precautions Introduction I-I-VIII Workshop Manual Issue 2 February 2005 Exhaust Fumes Engines must only be run where there is fume extraction equipment in operation or where there is adequate ventilation. Fire Precautions Tools and Equipment Use the recommended service tool where instructed to do so. Used Engine Oil Adequate means of skin protection and washing facilities should be provided. Health Protection Precautions • Wear protective clothing, including impervious gloves where practicable. • Do not put oily rags in pockets. • Avoid contaminating clothes with oil. • Overalls must be cleaned regularly. Discard un-washable clothes and oil impregnated footwear. • First aid treatment should be obtained immediately for open cuts or wounds. • Use barrier creams, apply before each work period to help the removal of oil from the skin. • Wash with soap and water to ensure all oil is removed. Preparations containing lanolin replace the natural skin oils which have been removed. • Do not use petrol, kerosene, diesel fuel, gas oil, thinners or solvents for washing skin. • If skin disorders develop, obtain medical advice. • Where practicable, degrease components prior to handling. • Where there is a risk of eye contact, eye protection should be worn. In addition, an eye wash facility should be provided. Environmental Protection It is illegal to pour used oil on the ground, down sewers or drains, or into water courses. The burning of used engine oil in small space heaters or boilers is not recommended unless emission control equipment is installed; in case of doubt, contact the Local Authority for advice on disposal facilities. Warning Do not breathe exhaust fumes. Exhaust fumes contain carbon monoxide. Carbon monoxide is a dangerous gas, which is colourless and odourless and can cause unconsciousness and may be fatal. Never start or leave the engine running in an enclosed, unventilated area. Warning Avoid skin contact with all exhaust system and engine components, engine fluids and escaping steam. They may be hot and will burn you. Warning Ensure that a suitable form of fire extinguisher is conveniently located near the work area. Warning Keep oils, solvents and combustible materials away from naked flames and other sources of ignition. Warning Ensure that NO SMOKING signs are posted around areas where combustible materials and vapour may be present and ensure that the warnings are strictly observed. Warning Ensure that dry sand is available to soak up any spillage of fuel or other flammable solutions. Warning Fume extraction equipment must be available and in full working order to remove combustible and toxic vapours. Warning All personnel should be aware of the fire drill procedures and precautions. Warning Do not leave tools, equipment, spilt oil, etc. around or on the work area. Warning Ensure that tools and equipment used are in good condition; do not use damaged or defective tools or equipment. Caution Do not apply heat in an attempt to free stiff nuts or fittings; as well as causing damage to protective coatings, the stray heat may damage electronic equipment, harnesses and brake lines. Warning Prolonged and repeated contact with used engine oils can cause serious skin disorders, including dermatitis and cancer. Avoid excessive contact, wash thoroughly after contact. In addition, observe all laws regarding the disposal of waste oil and toxic fluids. Warning Prolonged and repeated contact with used engine oils can cause serious skin disorders, including dermatitis and cancer. Avoid excessive contact, wash thoroughly after contact.

Lifting and Jacking Introduction Issue 2 February 2005 Workshop Manual I-I-IX Lifting and Jacking Safety Jacking Points This vehicle jacking points are at positions shown. The vehicle may also be jacked with the jack placed on the front subframe, front crossmember. Always use a jack with a rubber contact pad. Avoid the use of jacks with sharp contact pads which could damage the vehicle floor pan Always chock the opposite road wheels as well as applying the handbrake when using a hydraulic jack. To prevent body distortion, avoid single point or one side jacking with the tunnel shear panel removed. To avoid any danger of bodywork damage when using a hydraulic jack, the vehicle must only be lifted at the jacking points. Stands When carrying out work (other than a wheel change) which requires a wheel to be raised, a stand must be used, located at the jacking point, to provide a secure support for the vehicle. Workshop Hoist Use of a workshop hoist is recommended for all operations where vehicles must be raised. Follow manufacturers instructions. If using an adjustable arm type, ensure lifting pads are correctly positioned at the four jacking points before lifting. Warning Recommended procedures for lifting, jacking and towing must be strictly observed to ensure personal safety. Warning Always use a vehicle hoist, ramp or pit for working beneath the vehicle in preference to jacking. Warning Never rely on a jack to support a car independently, use axle stands or blocks carefully placed at jacking points to provide rigid support. Warning When working beneath a vehicle, chock wheels as well as applying handbrake. Warning Ensure vehicle is standing on firm, level ground before jacking or lifting. Warning Check lifting equipment has adequate capacity for load being lifted and is in full working order. Caution Do not jack the vehicle on the lower suspension arms (front or rear). Front Crossmember

Vehicle Recovery Introduction I-I-X Workshop Manual Issue 2 February 2005 Vehicle Recovery General The preferred method of vehicle recovery is by a flat bed, covered, transporter. The towing eye is primarily for emergency use when towing for short distances, e.g. removing vehicle if it is causing an obstruction or winching vehicle onto a flatbed transporter. If moving this vehicle in such a situation, install the towing eye to the bracket, which is located behind the registration number plate. Transporting If vehicle is to be transported on a trailer or flat bed transporter the handbrake must be applied and the road wheels must be chocked. Suspended Towing Take care when using 'spectacle frame' type towing equipment that the towing device is well clear of front or rear apron. Body damage may occur if vehicle passes over uneven road surfaces. Ensure the recovery team follow the following towing instructions: Front Suspended Tow Automatic Transmission Only 1. Switch the ignition ‘On’. 2. Pull back twice on both paddles, simultaneously, to force the gearbox into ‘Neutral’. Switch the ignition ‘Off’ within three seconds. Manual and Automatic Transmissions 3. Remove the ignition key from the ignition. 4. Raise the vehicle using a 'spectacle frame' type lifting device with a cradle positioned under each front wheel as indicated below. Rear Suspended Tow 1. Set the steering in the ‘straight ahead’ position. 2. Remove the ignition key from the ignition. Ensure the steering is locked in the straight ahead position. 3. Raise the vehicle using a 'spectacle frame' style lifting device where a cradle is positioned under each rear wheel as indicated below. Towing an Automatic Vehicle Towing Regulations In certain countries the registration number plate of the towing vehicle and an ‘ON TOW’ sign or warning triangle must be displayed in a prominent position at the rear of vehicle being towed. Towing by Another Vehicle This vehicle may be towed short distances by another vehicle provided that a speed of 48 km/h (30 mph) is not exceeded. Ensure that the towed vehicle gear selection is in ‘Neutral’ (manual) or position ‘N’ (automatic), the ignition key turned to position ‘II’ (to release steering lock and to render the horn, indicators and brake lights operational). Push-start Vehicle’s installed with automatic transmissions cannot be started by push-starting. Caution Take care to protect the paint work when installing the towing eye. Ensure the towing eye is tight. Caution Do not tow with ‘sling’ type equipment, damage to bodywork will result. Caution This vehicle installed with an automatic transmission can be towed on its driven wheels at not more than 70 km/h road speed and for a maximum distance of 500 km. The selector lever must be in Neutral (N). If the above speed and distance limits are exceeded, the automatic transmission will be severely damaged. Ward the brake booster will become ineffective after a few applications of the brakes. Be prepared for relatively heavy steering and the need for greatly increased brake pedal pressure.

2005-2010 ASTON MARTIN DB9 Workshop / Repair / Service Manual

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