2005-2009 Aston Martin V8 Vantage Service & Repair Manual

Workshop Manual Issue 6

Workshop Manual Aston Martin Lagonda Limited Banbury Road, Gaydon, WARWICK, Warwickshire, England, CV35 0DB Telephone: (01926) 644700 Fax: (01926) 644733 Aston Martin are constantly seeking to improve the specification, design and production of our 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 6 - March2010

Contents Issue 5, January 2010 Workshop Manual 0-0-3 V8 Vantage Workshop Manual Contents Introduction Welcome .............................................................. 0-0-6 Safety Precautions ................................................. 0-0-7 Lifting and Jacking ................................................. 0-0-9 Vehicle Recovery ................................................ 0-0-10 Vehicle Identification Number ............................ 0-0-11 Body System (01.00) Body Structure (01.01) .......................................... 1-1-4 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) ............................................. 1-8-1 Mirrors (01.09) ...................................................... 1-9-1 Seating (01.10) .................................................... 1-10-1 Glass, Frame and Mechanism (01.11) .................. 1-11-1 Instrument Panel (IP) (01.12) ............................... 1-12-1 Handles and Lock Mechanisms (01.14) ............... 1-14-1 Wipers and Washer System (01.16) ..................... 1-16-1 Convertible Roof and Roof Opening Subsystem (01.17)...............................................1-17-1 Bumpers (01.19) ................................................. 1-19-1 Restraining Devices (01.20) ................................. 1-20-1 Frame and Mounting (02.00) Subframes (02.03) ................................................. 2-1-2 Engine System (03.00) Engine Assembly....................................................3-0-3 Engine Structure (03.01) ........................................ 3-1-1 Lubrication System (03.02) .................................... 3-2-1 Cooling System (03.03) ......................................... 3-3-1 Fuel Charging System (03.04) ................................ 3-4-1 Accessory Drive System (03.05) ............................. 3-5-1 Engine Cranking System (03.06) ............................ 3-6-1 Valve Train (03.09) ............................................... 3-9-1 Engine Sealing (03.10) ......................................... 3-10-1 Power Conversion (03.11) ................................... 3-11-1 Evaporative Emissions (03.13) ............................. 3-11-1 Engine Management System (03.14) .................... 3-14-1 Throttle Control (03.16) ...................................... 3-16-1 Foot Operated Control (03.18)............................ 3-18-1 Suspension (04.00) Road Wheel Alignment (04.00) ............................. 4-0-2 Front Suspension (04.01)....................................... 4-1-1 Rear Suspension (04.02)........................................ 4-2-1 Shock Absorber System (04.03) ............................. 4-3-1 Road Wheels and Tyres (04.04) ............................ 4-4-1 Driveline (05.00) Driveshaft (05.01) ................................................. 5-1-2 Halfshafts (05.05) .................................................. 5-2-1 Brake System (06.00) Front Disc Brake (06.03) ....................................... 6-3-2 Rear Disc Brakes (06.04) ....................................... 6-4-1 Hand Brake (06.05) .............................................. 6-5-1 Brake Actuation System (06.06) ............................ 6-6-1 Power Brake System (06.07) ................................. 6-7-1 Anti-lock Braking System (06.09) ........................... 6-9-1 Transmission (07.00) Transmission Cooling (07.02) ................................ 7-0-2 Manual Transmission (07.03) ................................ 7-3-1 Automatic Control System (07.05) ......................... 7-5-1 Manual Control System (07.06) ............................. 7-6-1 Automatic Shifting Subsytem (07.11) .................. 7-11-1 Clutch (08.00) Clutch Controls (08.02) ......................................... 8-1-2 Exhaust (09.00) Exhaust Overview ................................................. 9-1-2 Silencer Assembly (09.01) ..................................... 9-1-3 Pipes and Supports (09.03) ................................... 9-2-1 Exhaust Protection (09.04) .................................... 9-3-1 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) ..................................... 11-4-1 Steering Column Switches (11.05) ....................... 11-5-1 Steering Wheel (11.06) ....................................... 11-6-1 Climate Control (12.00) Body Ventilation system (12.01) .......................... 12-1-2 Heater System (12.02) ........................................ 12-2-1 Air Conditioning (A/C) System (12.03) ................. 12-3-1 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 Vehicle Entertainment (15.00) Audio System (15.01) ..........................................15-1-2 Antenna (15.02) .................................................. 15-2-1 Vacuum Distribution (16.00) Body Vacuum System (16.01) ............................. 16-1-2 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

Contents 0-0-4 Workshop Manual Issue 5, January 2010 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 Electronic Features Modules (19.08)....................19-2-1 Appendix & Glossary (20.00) Diagnostic Ports.................................................. 20-1-2 Fluids/Capacities................................................. 20-1-3 Special Tools - Pictorial Index ............................. 20-1-4 Maintenance Schedules .................................... 20-1-12 Torque Figures ................................................. 20-1-15

Contents Issue 5, January 2010 Workshop Manual 0-0-5 Introduction Contents ................................................................. 0-3 Welcome................................................................ 0-0-6 Chapters ................................................................. 0-6 Chapter Navigation ................................................ 0-6 Page Numbering ..................................................... 0-6 Systems Classification Coding ................................ 0-6 Special Tools .......................................................... 0-0-6 Location References................................................ 0-6 Warnings, Cautions and Notes .............................. 0-0-6 Repairs and Replacements ..................................... 0-6 Safety Precautions ................................................. 0-0-7 Battery Disconnection ............................................ 0-7 Air Conditioning (A/C) System................................ 0-7 Chemical Handling and Storage ............................. 0-7 Electrical Equipment .............................................. 0-0-7 Exhaust Fumes ........................................................ 0-7 Fire Precautions ...................................................... 0-7 Tools and Equipment ............................................. 0-0-8 Used Engine Oil ...................................................... 0-8 Health protection precautions................................ 0-8 Environmental Protection ....................................... 0-8 Lifting and Jacking ................................................. 0-0-9 Safety ...................................................................... 0-9 Jacking Points ........................................................ 0-0-9 Lifting ..................................................................... 0-0-9 Workshop Hoist ..................................................... 0-9 Workshop Jack....................................................... 0-9 Stands .................................................................... 0-9 Vehicle Recovery.................................................. 0-0-10 General ................................................................. 0-10 Transporting ......................................................... 0-10 Suspended Towing............................................... 0-10 Adhere to Towing Regulations .............................. 0-10 Towing by Another Vehicle .................................. 0-10 Vehicle Identification Number ............................ 0-0-11 VIN Number Location .......................................... 0-11 Engine Number ..................................................... 0-12 Gearbox Number .................................................. 0-12

Welcome 0-0-6 Workshop Manual Issue 5, January 2010 Welcome This Workshop Manual is part of a suite of technical manuals provided for V8 Vantage. Other technical manuals include: • Parts manual • OBDII Diagnostic manual • Man hour schedules Chapters 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: Older workshop manuals would have Steering and Suspension together in one chapter. The structure now used places Steering and Suspension into their own chapters. When required references are made out to other chapters. Page Numbering The page numbering system used within this workshop manual is as follows: Systems Classification Coding Alongside the ‘System’ and ‘Subsystem’ section titles appear codes. For example Exhaust ‘09.00’ or Power Steering ‘11.02’. These codes relate to a Corporate Product Systems Classification (CPSC) and are designed to segregate the parts for engineering release and organise a variety of engineering data. 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 Appendix and Glossary for detailed operation procedures. A pictorial list of special service tools available for this vehicle can also be found in 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. The following Warnings, Cautions and Notes are used within this Owner’s Guide to call your attention to specific types of information. Warnings, Cautions and Notes 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 fitting 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 3- 2- 5 System, i.e. Engine system Subsystem, i.e. Engine lubrication system Page Number, i.e. Number within subsystem 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 Issue 5, January 2010 Workshop Manual 0-0-7 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 contains a list of particular safety precautions which should be observed; it is not intended to be exhaustive. Battery Disconnection When a service manual procedure requires the vehicle battery to be disconnected - always physically disconnect the vehicle battery earth (Negative) lead. Do not use the ‘Battery Disconnect Switch’. After reconnecting the vehicle battery the following items will have to be reset or re-learnt: • Radio pre-sets • Windows • 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. The following precautions should be observed. • Strictly adhere to handling and safety information found on containers and labels. • Do not store chemicals in unlabelled or incorrectly labelled containers. • 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. • Do not mix chemicals unless instructed to do so following manufacturers guidelines. • Do not inhale chemical materials to determine identity, they may be toxic. • Do not use petrol, kerosene, diesel fuel, gas oil, thinners or solvents for washing skin. • Containers whose capacity is over 25 litres (5 gallons) require a bund wall in order to contain spillages. • 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. • Ensure that adequate ventilation is provided when volatile de-greasing agents are being used. • Avoid splashing the skin, eyes and clothing. • Clean chemicals from the skin and clothing as soon as possible after soiling. • Wear protective clothing such as goggles, non porous gloves and apron when handling battery acid and other corrosive and toxic substances. Electrical Equipment • Ensure that electrical equipment is in safe working order before use. • Inspect power leads of all mains electrical equipment for damage and security, and check that it is properly earthed. • Ensure that electrical equipment is protected by a fuse of the correct current rating. • Disconnect the battery before commencing repair operations to the electrical system, fuel system and engine or when working beneath the vehicle. Exhaust Fumes Engines should not be run in confined spaces as exhaust fumes contain harmful and toxic substances including carbon monoxide which can prove fatal if inhaled. Engines must only be run where there is fume extraction equipment in operation or where there is adequate ventilation. Fire Precautions • Ensure that a suitable form of fire extinguisher is conveniently located near the work area. • Keep oils, solvents and combustible materials away from naked flames and other sources of ignition. • 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. • Ensure that dry sand is available to soak up any spillage of fuel or other flammable solutions. • Fume extraction equipment must be available and in full working order to remove combustible and toxic vapours. • All personnel should be aware of the fire drill procedures and precautions. 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, PERCHLORETHYLENE.

Safety Precautions 0-0-8 Workshop Manual Issue 5, January 2010 Tools and Equipment • Do not leave tools, equipment, spilt oil, etc. around or on the work area. • Ensure that tools and equipment used are in good condition; do not use damaged or defective tools or equipment. • 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. • Use the recommended service tool where instructed to do so. Used Engine Oil Prolonged and repeated contact with mineral oil will result in the removal of natural fats from the skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contaminants which may cause skin cancer. Adequate means of skin protection and washing facilities should be provided. Health protection precautions • Avoid prolonged and repeated contact with oils, particularly used engine oil. • 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.

Lifting and Jacking Issue 5, January 2010 Workshop Manual 0-0-9 Lifting and Jacking Safety • Recommended procedures for lifting, jacking and towing must be strictly observed to ensure personal safety. • Always use a vehicle hoist, ramp or pit for working beneath the vehicle in preference to jacking. • Never rely on a jack to support a car independently, use axle stands or blocks carefully placed at jacking points to provide rigid support. • When working beneath a vehicle, chock wheels as well as applying handbrake. • Ensure vehicle is standing on firm, level ground before jacking or lifting. • Check lifting equipment has adequate capacity for load being lifted and is in full working order. Jacking Points This vehicle jacking points are at positions shown. May also be jacked on the front subframe front crossmember Always use a jack with a rubber contact pad. Avoid use of jacks with sharp contact pads which would damage 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. Lifting 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. Workshop Jack 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. 00-00-001

Vehicle Recovery 0-0-10 Workshop Manual Issue 5, January 2010 Vehicle Recovery General Preferred method of vehicle recovery is by flat bed 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 in the lower grille aperture. 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. Front Suspended Tow 1. Remove the ignition key from the ignition. 2. 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. Remove the ignition key from the ignition. Ensure the steering is locked in the straight ahead position. 2. Raise the vehicle using a 'spectacle frame' style lifting device where a cradle is positioned under each rear wheel as indicated below. Adhere to Towing Regulations In certain countries the registration number of 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 the towed vehicle gear selection is in ‘Neutral’ with ignition key turned to position ‘II’ to release steering lock and to render horn, indicators and brake lights operational. 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 as this could result in damage to the bodywork. WARNING WHEN THE ENGINE IS NOT RUNNING, THE STEERING WILL NO LONGER BE POWER-ASSISTED AND 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.

2005-2009 Aston Martin V8 Vantage Service & Repair Manual

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