DB9
Workshop Manual
Issue 2
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 |
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Contents
Introduction |
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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) |
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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) |
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Subframes (02.03)................................................. |
2-1-2 |
Engine System (03.00) |
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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) |
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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 |
DB9 Workshop Manual
Driveline (05.00) |
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Driveshaft (05.01) ................................................. |
5-1-2 |
Rear Drive System (05.02) .................................... |
5-2-1 |
Halfshafts (05.05).................................................. |
5-3-1 |
Brake System (06.00) |
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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) |
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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) |
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Clutch Controls (08.02)......................................... |
8-2-1 |
Exhaust (09.00) |
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Exhaust Overview ................................................. |
9-1-2 |
Silencer Assembly (09.01) ..................................... |
9-1-3 |
Pipes and Supports (09.03) ................................... |
9-2-1 |
Fuel (10.00) |
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Fuel Tank and Lines (10.01)................................ |
10-1-2 |
Steering (11.00) |
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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) |
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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) |
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Instrument Cluster (13.01) .................................. |
13-1-2 |
Power Supply (14.00) |
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Battery System (14.01) ........................................ |
14-1-2 |
Alternator and Regulator System (14.02) ............. |
14-2-1 |
Issue 2 February 2005 |
Workshop Manual |
I-I-III |
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Vehicle Entertainment (15.00) |
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Audio System ..................................................... |
15-1-1 |
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Vacuum Distribution (16.00) |
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Body Vacuum System (16.01)............................. |
16-1-1 |
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Lighting (17.00) |
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Front Lights (17.01) ............................................ |
17-1-2 |
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Interior Lighting (17.02)...................................... |
17-2-1 |
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Rear Lights (17.03) ............................................. |
17-3-1 |
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Lighting Mechanisms (17.04) .............................. |
17-4-1 |
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Electric Distribution/Electronic Control (18.00) |
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Wiring and Circuit Protection (18.01) ................. |
18-1-2 |
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Vehicle Control System (18.08) .......................... |
18-2-1 |
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Electronic Features (19.00) |
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Active Anti-Theft System (19.01)......................... |
19-1-2 |
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Appendix & Glossary |
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Diagnostic Ports................................................... |
20-1-2 |
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Fluids/Capacities.................................................. |
20-1-3 |
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Abbreviations ...................................................... |
20-1-3 |
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Terms.................................................................. |
20-1-3 |
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Special Tools - Pictorial Index .............................. |
20-1-4 |
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Specialist Tool Operation .................................... |
20-1-8 |
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Maintenance Schedules..................................... |
20-1-11 |
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Torque Figures .................................................. |
20-1-14 |
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Torque Conversion Tables ................................. |
20-1-31 |
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I-I-IV |
Workshop Manual |
Issue 2 February 2005 |
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Introduction |
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Contents |
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Welcome................................................................ |
I-I-VI |
Vehicle Recovery .................................................... |
I-I-X |
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Chapters ................................................................ |
I-VI |
General.................................................................... |
I-X |
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Chapter Navigation ................................................ |
I-VI |
Transporting............................................................ |
I-X |
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Numbering ............................................................ |
I-VI |
Suspended Towing ................................................. |
I-X |
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Special Tools.......................................................... |
I-VI |
Front Suspended Tow........................................... |
I-X |
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Location References............................................... |
I-VI |
Rear Suspended Tow............................................ |
I-X |
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Warnings, Cautions and Notes.............................. |
I-VI |
Towing an Automatic Vehicle ................................. |
I-X |
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Repairs and Replacements .................................... |
I-VI |
Towing Regulations................................................. |
I-X |
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Safety Precautions ................................................ |
I-I-VII |
Towing by Another Vehicle..................................... |
I-X |
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Battery Disconnection .......................................... |
I-VII |
Push-start ................................................................ |
I-X |
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Air Conditioning (A/C) System.............................. |
I-VII |
Identification Numbers ......................................... |
I-I-XI |
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Chemical Handling and Storage........................... |
I-VII |
Vehicle Identification Number (VIN)...................... |
I-XI |
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Electrical Equipment............................................. |
I-VII |
VIN Number Location............................................ |
I-XI |
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Exhaust Fumes ..................................................... |
I-VIII |
Engine Number..................................................... |
I-XII |
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Fire Precautions................................................... |
I-VIII |
Gearbox Number.................................................. |
I-XII |
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Tools and Equipment........................................... |
I-VIII |
Automatic Gearbox............................................... |
I-XII |
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Used Engine Oil................................................... |
I-VIII |
Manual Gearbox................................................... |
I-XII |
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Health Protection Precautions............................. |
I-VIII |
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Environmental Protection.................................... |
I-VIII |
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Lifting and Jacking ................................................. |
I-I-IX |
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Safety ..................................................................... |
I-IX |
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Jacking Points ........................................................ |
I-IX |
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Stands................................................................. |
I-IX |
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Workshop Hoist..................................................... |
I-IX |
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Issue 2 February 2005 |
Workshop Manual |
I-I-V |
Welcome
Introduction
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
03. 02.
System, i.e. Engine system
Subsystem, i.e. Engine lubrication system
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
Warning 
Identifies procedures which must be followed precisely to help avoid the risk of personal injury.
Cautions
Caution
Provided to indicate procedures which must be followed precisely to reduce the possibility of damage to the vehicle.
Notes
Provided to indicate procedures which will help to avoid difficulties in the operation of the vehicle.
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
I-I-VI |
Workshop Manual |
Issue 2 February 2005 |
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. 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
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.
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 
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.
Issue 2 February 2005 |
Workshop Manual |
I-I-VII |
Safety Precautions
Introduction
Exhaust Fumes
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.
Engines must only be run where there is fume extraction equipment in operation or where there is adequate ventilation.
Fire Precautions
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.
Tools and Equipment
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.
Used Engine Oil
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.
Adequate means of skin protection and washing facilities should be provided.
Health Protection Precautions
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.
•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.
Use the recommended service tool where instructed to do so.
I-I-VIII |
Workshop Manual |
Issue 2 February 2005 |
Lifting and Jacking
Introduction
Lifting and Jacking
Safety
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.
The vehicle may also be jacked with the jack placed on the front subframe, front crossmember.
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.
Jacking Points
Caution
Do not jack the vehicle on the lower suspension arms (front or rear).
This vehicle jacking points are at positions shown.
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.
Issue 2 February 2005 |
Workshop Manual |
I-I-IX |
Vehicle Recovery
Introduction
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.
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.
Caution |
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Take care to protect the paint work when installing the |
Towing an Automatic Vehicle |
towing eye. Ensure the towing eye is tight. |
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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
Caution
Do not tow with ‘sling’ type equipment, damage to bodywork will result.
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.
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.
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
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.
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.
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I-I-X |
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Workshop Manual |
Issue 2 February 2005 |
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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 fundamental data on the build site, date and initial configuration of the vehicle.
S C F A C 1 3 A 4 1 G A 0 0 0 0 1
Code for AML
Restraint System
Transmission and Steering
Body Type
Engine Type
Calculated Check Digit
Model Year
Manufacturing Plant
Series Identifier
Sequential Chassis Number
VIN Number Location
The VIN number is stamped / plated in the following locations:
Under the lower edge of the windscreen. |
Front of the engine bay. |
VIN Number
01-00-004
Stamped on the floorpan in the RH front footwell.
VIN Number
01-00-011
Issue 2 February 2005 |
Workshop Manual |
I-I-XI |
Identification Numbers
Introduction
Engine Number
The engine number is stamped on the LH side of the engine block.
Gearbox Number
Automatic Gearbox
The automatic gearbox number plate is located on the LH side of the gearbox.
Manual Gearbox
To follow.
Image to Follow
I-I-XII |
Workshop Manual |
Issue 2 February 2005 |
Contents
Body Structure (01.01)........................................... |
1-1-3 |
Overview ................................................................ |
1-3 |
Front End (01.02)................................................... |
1-2-1 |
Front Wings ............................................................ |
2-1 |
Specifications......................................................... |
2-1 |
Maintenance.......................................................... |
2-1 |
Front Wing .......................................................... |
2-1 |
Body Closures (01.03) ........................................... |
1-3-1 |
Specifications.......................................................... |
3-1 |
Doors .................................................................... |
3-1 |
Boot Lid................................................................. |
3-1 |
Bonnet................................................................... |
3-1 |
Maintenance........................................................... |
3-2 |
Doors .................................................................... |
3-2 |
Removal.............................................................. |
3-2 |
Installation .......................................................... |
3-2 |
New Door Assembly .............................................. |
3-3 |
Preliminary Hinge Setup ...................................... |
3-3 |
Boot Lid................................................................. |
3-4 |
Removal.............................................................. |
3-4 |
Installation .......................................................... |
3-4 |
Bonnet................................................................... |
3-5 |
Removal.............................................................. |
3-5 |
Installation / Realignment .................................... |
3-5 |
Interior Trim (01.05).............................................. |
1-4-1 |
Specifications.......................................................... |
4-1 |
Maintenance........................................................... |
4-1 |
IP Trim................................................................... |
4-1 |
Remove............................................................... |
4-1 |
Installation Notes ................................................ |
4-1 |
Roof Trim .............................................................. |
4-2 |
Removal.............................................................. |
4-2 |
Installation .......................................................... |
4-2 |
Door Trim.............................................................. |
4-3 |
Removal.............................................................. |
4-3 |
Installation .......................................................... |
4-4 |
Rear Trim............................................................... |
4-5 |
Removal (Coupe)................................................. |
4-5 |
Install (Coupe)..................................................... |
4-6 |
Removal (Volante) ............................................... |
4-6 |
Install (Volante) ................................................... |
4-6 |
Boot Trim .............................................................. |
4-7 |
Removal.............................................................. |
4-7 |
Installation ............................................................. |
4-7 |
Exterior Trim (01.08) ............................................. |
1-5-1 |
Maintenance........................................................... |
5-1 |
Side Trim ............................................................... |
5-1 |
Removal.............................................................. |
5-1 |
Installation .......................................................... |
5-1 |
Sill Trim ................................................................. |
5-2 |
Remove............................................................... |
5-2 |
Installation .......................................................... |
5-2 |
Body System (01.00)
Mirrors (01.09) ...................................................... |
1-6-1 |
Specifications ......................................................... |
6-1 |
Maintenance........................................................... |
6-1 |
Door Mirrors.......................................................... |
6-1 |
Removal.............................................................. |
6-1 |
Installation .......................................................... |
6-1 |
Seating (01.10)....................................................... |
1-7-1 |
Description............................................................. |
7-1 |
Heated Seats ......................................................... |
7-1 |
Seat Module .......................................................... |
7-1 |
Specifications ........................................................ |
7-1 |
Maintenance........................................................... |
7-1 |
Front Seat .............................................................. |
7-1 |
Removal.............................................................. |
7-1 |
Installation .......................................................... |
7-2 |
Seat Base Control Motors....................................... |
7-2 |
Seat Module .......................................................... |
7-2 |
Removal.............................................................. |
7-2 |
Installation .......................................................... |
7-2 |
Seat Module Calibration ........................................ |
7-3 |
Rear Seats.............................................................. |
7-3 |
Removal (Coupe) ................................................ |
7-3 |
Installation (Coupe) ............................................. |
7-3 |
Removal (Volante) ............................................... |
7-4 |
Installation (Volante)............................................ |
7-4 |
Glass, Frame and Mechanism (01.11)................... |
1-8-1 |
Description............................................................. |
8-1 |
Frameless doors ..................................................... |
8-1 |
Specifications......................................................... |
8-1 |
Maintenance........................................................... |
8-1 |
Glass Regulator ...................................................... |
8-1 |
Removal.............................................................. |
8-1 |
Installation .......................................................... |
8-2 |
Door Glass............................................................. |
8-3 |
Removal.............................................................. |
8-3 |
Installation .......................................................... |
8-4 |
Door Glass Setup ................................................... |
8-5 |
Rear Quarter Glass (Coupe) ................................... |
8-6 |
Remove .............................................................. |
8-6 |
Installation .......................................................... |
8-6 |
Rear Quarter Glass (Volante).................................. |
8-6 |
Remove .............................................................. |
8-6 |
Installation .......................................................... |
8-8 |
Instrument Panel (IP) (01.12) ................................ |
1-9-1 |
Specifications ......................................................... |
9-1 |
Maintenance........................................................... |
9-1 |
IP .......................................................................... |
9-1 |
Removal.............................................................. |
9-1 |
Installation .......................................................... |
9-3 |
Issue 2 February 2005 |
Workshop Manual |
1-1-1 |
Handles and Lock Mechanisms (01.14).............. |
1-10-1 |
Description ........................................................... |
10-1 |
Vehicle Key / Remote Transmitter......................... |
10-1 |
Central Locking System ........................................ |
10-1 |
Remote Transmitter.............................................. |
10-1 |
Fuel Filler Assembly.............................................. |
10-1 |
Manual Boot Release............................................ |
10-1 |
Boot Emergency Release ...................................... |
10-1 |
Specifications ........................................................ |
10-2 |
Maintenance ......................................................... |
10-2 |
Door Handle / Latch Unit..................................... |
10-2 |
Removal ............................................................ |
10-2 |
Installation ........................................................ |
10-3 |
Wipers and Washer System (01.16).................... |
1-11-1 |
Headlamp Washing .............................................. |
11-2 |
Specifications ........................................................ |
11-2 |
Maintenance ......................................................... |
11-2 |
Windscreen Wiper Motor..................................... |
11-2 |
Removal ............................................................ |
11-2 |
Installation ........................................................ |
11-4 |
Wiper Arms.......................................................... |
11-5 |
Removal ............................................................ |
11-5 |
Installation ........................................................ |
11-5 |
Convertible Roof (01.17)..................................... |
1-12-1 |
Description ........................................................... |
12-1 |
Specifications ........................................................ |
12-1 |
Maintenance ......................................................... |
12-2 |
Roof..................................................................... |
12-2 |
Removal ............................................................ |
12-2 |
Installation ........................................................ |
12-3 |
Roof Material ....................................................... |
12-3 |
Removal ............................................................ |
12-3 |
Installation ........................................................ |
12-5 |
Weather Seals ...................................................... |
12-9 |
Removal ............................................................ |
12-9 |
Installation ........................................................ |
12-9 |
Roof Pump........................................................... |
12-9 |
Removal ............................................................ |
12-9 |
Installation ...................................................... |
12-11 |
Roof Module...................................................... |
12-12 |
Removal .......................................................... |
12-12 |
Installation ...................................................... |
12-12 |
Roof Lid Hydraulic Rams.................................... |
12-12 |
Removal .......................................................... |
12-12 |
Installation ...................................................... |
12-13 |
Bumpers (01.19) .................................................. |
1-13-1 |
Front Bumper........................................................ |
13-1 |
Specifications ....................................................... |
13-1 |
Maintenance........................................................ |
13-1 |
Removal............................................................ |
13-1 |
Installation ........................................................ |
13-2 |
Rear Bumper......................................................... |
13-3 |
Specifications ....................................................... |
13-3 |
Maintenance........................................................ |
13-3 |
Removal............................................................ |
13-3 |
Installation ........................................................ |
13-5 |
Restraining Devices (01.20)................................. |
1-14-1 |
Seat Belts .............................................................. |
14-1 |
Pre-tensioner and Load Limiting Systems ............ |
14-1 |
Emergency Locking Retractor (ELR) ..................... |
14-2 |
Automatic Locking Retractor (ALR) ..................... |
14-2 |
Specifications ....................................................... |
14-2 |
Airbag System ....................................................... |
14-3 |
Airbag Deployment .......................................... |
14-3 |
Dual Inflation Technology .................................. |
14-3 |
Driver airbag Module......................................... |
14-3 |
Passenger Airbag Module ................................... |
14-3 |
Side Airbag Module ........................................... |
14-3 |
Clockspring ....................................................... |
14-3 |
Restrains Control Module (RCM) ........................ |
14-4 |
Impact Sensors .................................................. |
14-4 |
Specifications........................................................ |
14-4 |
Maintenance........................................................ |
14-4 |
Driver Airbag..................................................... |
14-4 |
Passenger Airbag................................................ |
14-4 |
Side Impact Airbag ............................................ |
14-5 |
Deployable Rollbars ............................................. |
14-6 |
Specifications ....................................................... |
14-6 |
Maintenance........................................................ |
14-6 |
Rollbar Unit....................................................... |
14-6 |
Rollbar Sensor ................................................... |
14-8 |
1-1-2 |
Workshop Manual |
Issue 2 February 2005 |
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. In addition, the roof panel is connected to the rear quarter panels through ultrasonic welds.
The composite front wings are bolted to the structure.
At no time should the body structure be subjected to temperatures in excess of 120°C (248°F).
01-01-020
Issue 2 February 2005 |
Workshop Manual |
1-1-3 |
Body Structure (01.01)
Body System (01.00)
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1-1-4 |
Workshop Manual |
Issue 2 February 2005 |
Front End (01.02)
Body System (01.00)
Body System (01.00)
Front End (01.02)
Front Wings
Specifications
2
1
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3 |
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4 |
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Wing Standard (mm) |
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Item |
1 |
2 |
3 |
4 |
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Nominal gap |
3.5 |
2.0 |
3.75 |
3.0 |
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Tolerance |
±0.75 |
+0.5 / -0.0 ± 0.75 |
±0.5 |
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Flush |
-0.0 |
0.0 |
0.0 |
-0.5 |
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Tolerance |
±1.5 |
+0.0 / -0.5 ±1.5 |
±0.5 |
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Taper |
N/A |
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Symmetry |
N/A |
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Torque Figures |
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Description |
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Nm. |
lbs / ft. |
Wing Top |
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8 |
6 |
Wing Top Single nut |
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Tight with |
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‘Threadlock’ |
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Lower Rear |
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8 |
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6 |
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Slam panel |
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8 |
6 |
PCM Bracket |
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10 |
7 |
Bonnet Damper |
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25 |
18 |
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Maintenance
Front Wing
Repair Operation Time (ROT)
Item |
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Code |
Front Wing Renew |
(LH) |
01.02.KB |
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(RH) |
01.02.LB |
Removal
1.Disconnect the vehicle battery.
2.Remove the wing top nut.
If using a two post vehicle lift, remove the screws that secure 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. (Refer to ’Jacking Points’, page I-I-IX)
3. Remove the front road wheel and road wheel arch liner.
Issue 2 February 2005 |
Workshop Manual |
1-2-1 |
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 1-13-1).
6.Remove the slam panel (bolts x12). Remove the front grill bolt (x2).
01-02-007
1-2-2 |
Workshop Manual |
Issue 2 February 2005 |
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.Connect the wing to the bumper.
5.Install bolts to the wing top edge. Do not tighten.
Front bolt on each wing
The two lower rear wing bolts have the same bolt / washer arrangement.
9.Lift from the rear lower edge to disengage the wing from the two loosened bolts. Pull the wing from the body.
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Issue 2 February 2005 |
Workshop Manual |
1-2-3 |
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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 ’Road Wheel Nut Torque Tightening’, page 4-5-7).
11.Connect the vehicle battery.
1-2-4 |
Workshop Manual |
Issue 2 February 2005 |
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Body Closures (01.03) |
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Body System (01.00) |
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Body System (01.00) |
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Body Closures (01.03) |
Boot Lid |
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Specifications |
1 |
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Doors |
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Door Standard (mm) |
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Item |
1 |
*2 |
3 |
4 |
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Nominal gap |
3.5 |
3.00 |
3.00 |
3.75 |
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Tolerance |
±0.75 |
±1.0 |
±1.0 |
± 0.75 |
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Flush |
0.0 |
-1.0 |
-1.0 |
0.0 |
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Tolerance |
±1.5 / 0.0 |
+0.0 / -1.0 |
±1.0 |
±1.5 |
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Taper |
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N/A |
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Symmetry |
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N/A |
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*Flushness blends to 0.0 at the rear quarter
*Gap blends to 3.5 at rear quarter
Torque Figures
Description |
Nm. |
lb. / ft. |
Hinge to Door |
47.5 |
33.5 |
Hinge to Body |
36 |
26.5 |
Door Striker plate |
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2 |
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Boot Standard (mm) |
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Item |
1 |
2 |
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Nominal gap |
3.5 |
3.5 |
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Tolerance |
±0.75 |
±1.0 |
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Flush |
-0.5 |
N/A |
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Tolerance |
+0.5 / -1.0 |
N/A |
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Taper |
1 mm Max. across the length |
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Symmetry |
1 mm Max. difference LH to RH |
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Torque Figures |
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Description |
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Nm |
lb. / ft. |
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Hinge to Body |
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25 |
18 |
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Bonnet
1
Bonnet Standard (mm) |
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Item |
1 |
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Nominal gap |
3.5 |
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Tolerance |
±0.75 |
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Flush |
-0.0 |
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Tolerance |
±1.5 |
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Taper |
N/A |
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Symmetry |
N/A |
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Torque Figures |
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Description |
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Nm |
lb. / ft. |
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Hinge to Body |
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25 |
18 |
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Issue 2 February 2005 |
Workshop Manual |
1-3-1 |
Body Closures (01.03)
Body System (01.00)
Maintenance |
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5. Lift the door off the support studs and withdraw the |
Doors |
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door enough to gain access to the door wiring harness |
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plug. Disconnect the wiring harness plug. |
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Repair Operation Time (ROT) |
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Item |
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Code |
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Remove and reinstall |
LH |
01.03.EA |
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RH |
01.03.FA |
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Removal
Warning 
The doors are heavy. Removal is a two person operation.
Caution
Before removing the door ensure that the vehicle body work is sufficiently protected from possible damage.
1.Disconnect the vehicle battery.
2.Open the vehicle door.
3.Slightly loosen the door hinge lock screws (x2).
6. Withdraw the door from the vehicle and install on service tool (Refer to ’501-F111 (Door Service Trolley)’, page 20-1-8).
Installation
Warning 
The doors are heavy. Replacement is a two person operation.
Caution
Before installing the door ensure that the vehicle body work is sufficiently protected from possible damage.
1. |
Place the door to the vehicle. Connect the door wiring |
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harness plug. |
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4. Remove part of the roadwheel arch liner to gain access 2. |
Align the door to the upper and lower hinges. Install the |
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to the door check rod. Disconnect the door check rod. |
door onto the hinges. |
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3. Connect the door check rod. Install the roadwheel arch liner.
4. Align the door. Manoeuvre the door to achieve correct gaps and flush (add / remove shims as required). Tighten the bolts. Do not torque.
1-3-2 |
Workshop Manual |
Issue 2 February 2005 |
Body Closures (01.03)
Body System (01.00)
5. Connect the vehicle battery.
Warning 
Never touch the door lock linkage with electrical power available to the door. The window mechanism can move and trap hands, arms, etc. in door frame.
6.Check door alignment and closure of the door catch. Adjust striker plate if required.
7.When satisfied with the door install - torque the hinge bolts.
•Hinge to Body - 36 Nm.
•Hinge to Door - 47.5 Nm.
New Door Assembly
Repair Operation Time (ROT)
Item |
|
Code |
Remove and install |
LH |
01.03.CB |
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RH |
01.03.DB |
Preliminary Hinge Setup
1.Install the door onto the hinges.
2.Place a weight of 16 kg (to compensate for weight of
door windows, locks etc.) hanging from inner door skin as shown.
Weight and position are critical to accurately simulate weight and distribution of door furniture. Adjustment is difficult on a fully installed door.
3. If removed, install the front wing (Refer to ’Front Wing’, page 1-2-1).
4. Gently close the door. Check for an acceptable initial install.
5. Align the door. Manoeuvre the door to achieve correct gaps and flush (add / remove shims as required). Tighten the bolts. Do not torque.
6. Open the door and torque all hinge bolts. Remove the door weight.
• Hinge to Body - 36 Nm.
• Hinge to Door - 47.5 Nm.
8.Check for:
•Correct operation of all door lock functions.
•Correct operation and sealing of the door window.
7. Release the hinge locking screws and remove the door for installation of window, locks etc.
Issue 2 February 2005 |
Workshop Manual |
1-3-3 |
Body Closures (01.03)
Body System (01.00)
Boot Lid |
4. |
Lower the boot lid. Check for correct alignment and |
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readjust if required. |
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Repair Operation Time (ROT) |
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5. |
Fully raise the boot lid. Torque the hinge bolts to 25 |
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Item |
Code |
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Nm. |
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Remove and reinstall |
01.03.BB |
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Removal
Warning 
The boot lid is heavy. Removal / replacement is a two person operation.
1.Open the boot lid.
2.Remove the boot lid trim panel (Fir trees).
3. Disconnect the boot lid harness.
4.Slightly loosen the bolts (x4) that secure the boot lid to the boot lid hinges.
5.Support the boot lid. Remove the hinge bolts.
6.Withdraw the boot lid from the vehicle.
Installation
1.Align the boot lid to it’s hinges. Install bolts (x4) sufficiently to manoeuvre the boot lid on it’s hinges. Gently lower the boot lid rear edge, ensure the front corners do not touch the rear wings.
2.Align the boot lid front edge centrally in the boot aperture. Manoeuvre as required to achieve correct gaps.
3.Partially raise the boot lid and ‘nip’ up the hinge bolts.
6.Gently close the boot lid. Check for correct engagement of the boot latch.
Adjust the boot latch if required. Torque the boot latch bolts, to 9 Nm.
7.Connect the boot lid wiring harness plugs.
8.Fully close the boot lid.
Check for correct operation of the boot release switch and remote transmitter boot lid enable.
9.Install the boot lid trim.
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1-3-4 |
Workshop Manual |
Issue 2 February 2005 |
|
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.
4.With the bonnet supported, disconnect the gas struts and remove the hinge bolts (x4).
5. Withdraw the bonnet from the vehicle.
Installation / Realignment
Warning 
The bonnet is heavy. Replacement is a two person operation.
1.Align the bonnet to it’s hinges. Install bolts (x4) sufficiently to manoeuvre the bonnet on it’s hinges. Gently lower the bonnet. Adjust so that the corners do not touch the wings at the front and rear. Align the bonnet front edge centrally in the aperture.
2.Partially raise the bonnet. ‘Nip’ up one hinge bolt either side.
3.Lower the bonnet. Check for correct alignment. Readjust if required.
4.Fully raise the bonnet. Torque all hinge bolts to 25 Nm.
5.Install the bonnet gas struts.
6.Gently close the bonnet. Check for correct engagement of the bonnet latch. Adjust if required to achieve the flush specification.
•Turn the nut anti-clockwise to raise or clockwise to lower the bonnet catch until the bonnet is flush with the wings when closed.
7.Fully close the bonnet. Check for correct operation of the bonnet release lever.
Issue 2 February 2005 |
Workshop Manual |
1-3-5 |
Body Closures (01.03)
Body System (01.00)
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1-3-6 |
Workshop Manual |
Issue 2 February 2005 |
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.
Specifications
Torque Figures
Description |
Nm |
lb. / ft. |
Door Handle |
9 |
6.5 |
Seat Belt Mounts |
35 |
26 |
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Maintenance
IP Trim
If required, removal of the IP trim can |
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be achieved while the IP is in the |
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vehicle. |
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Remove |
9 |
1.Panel (1)- Pull off.
2.Hood (2) - Pull off.
3.Panel (3) - Pull off.
4.Panel (4) - Pull off. Disconnect the air temperature pipe.
5.Panel (5) - Front, screws (x3)
6.Glove box.
6.1 Pull of the outer trim panel. |
6.1 |
Disconnect the glovebox release switch wiring harness plug.
6.2Release the damper cord.
6.3Remove screws (x3) from the
glovebox door hinge. Remove |
6.3 |
door. |
6.4Remove screws (x4) from the sight shield. Remove the sight shield and glovebox.
7.Panel, Airbag (7).
Caution
Withdraw the airbag panel carefully. The airbag panel can crease if forced out.
7.1Remove screws (x3).
7.2Lift from the front edge. Withdraw out of clips (x3).
8.Remove the airbag.
Warning 
When removed, place the airbag in a sercure container to prevent personal injuries if the airbag activates.
8.1Disconnect the wiring harness plugs (x2).
8.2Remove bolts (x4). Withdraw the airbag.
9.Panel (9) - Screws (x2), then pull off.
10.Panel (10) - Screws (x4).
10
7
2 5
3 |
1 |
6.4 |
4 |
11.If required, remove the center stack.
11.1Pull off the veneer panel (Service tool No. TBA). Disconnect the wiring harness plugs.
11.2Remove the speaker grill - Screws (x2).
11.3Remove the center panel (Radio etc.) - Screws (x4)
11.4Remove the center stack - Screws (x6).
11.5Remove the media player - Screws (x2). Disconnect the wiring harness plugs.
Installation Notes
The panels, etc., are best replaced in the order they were removed. Note the following:
1.When installing the glovebox shield ensure that the tab in the top centre locates into the slot in the substrate.
Issue 2 February 2005 |
Workshop Manual |
1-4-1 |
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’.
2.Remove the interior mirror (screw x1).
3.Remove the reading lamp pod
(clips x2, screw x1, wiring harness plugs x2)
4. Remove the sun visors (screws
x2 (x2).
The front headlining will fall away.
5. Remove the headlining.
Held in place with ‘FirTrees’ and two velcro panels at the rear.
Installation
1. Install the roof lining.
2.Install the front headling.
While holding the front headling in place install the sun visors.
3.Install the interior mirror.
4.Install the cant rails.
Place the front of the cant rail into location at the IP, and work towards the rear, locating the ‘FirTrees’.
1-4-2 |
Workshop Manual |
Issue 2 February 2005 |
Interior Trim (01.05)
Body System (01.00)
Door Trim
Removal
5. Remove the door mirror cheater panel.
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.Remove the door handle trim plate and disconnect the release cable.
7. From the outside remove screws (x2).
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Issue 2 February 2005 |
Workshop Manual |
1-4-3 |
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Interior Trim (01.05)
Body System (01.00)
8. Remove the door trim panel screws (x6). Withdraw the |
Installation |
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door trim panel to gain access to the window and mirror |
1. |
Place the door trim panel to the door and connect the |
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switches. Disconnect the switches. |
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wiring harness plugs. |
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2. |
Install the door trim panel screws (x6). |
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3. |
Install screws (x2). |
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4. Install the outer weather seal strip.
5. Install the door mirror cheater panel.
6. Install the door pull
6.1 Connect the door inner release cable.
6.2 Install the door pull trim plate.
6.3 Install the door handle. Torque to 9 Nm. 7. Connect the vehicle battery.
1-4-4 |
Workshop Manual |
Issue 2 February 2005 |
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