Aston Martin V8 Vantage (Issue 6) - Service Manual / Repair Manual

ASTON MARTIN V8 VANTAGE - WORKSHOP, SERVICE, REPAIR MANUAL

- English Service Manual / Repair Manual, to vehicles Aston Martin V8 Vantage (Issue 6).

- Manual Date: March 2010

CONTENTS:

00-00 INTRODUCTION
- CONTENTS
- WELCOME
-- Chapters
-- Chapter Navigation
-- Page Numbering
-- Systems Classification Coding
- SPECIAL TOOLS
-- Location References
- WARNINGS, CAUTIONS AND NOTES
-- Repairs and Replacements
- SAFETY PRECAUTIONS
-- Battery Disconnection
-- Air Conditioning (A/C) System
-- Chemical Handling and Storage
- ELECTRICAL EQUIPMENT
-- Exhaust Fumes
-- Fire Precautions
- TOOLS AND EQUIPMENT
-- Used Engine Oil
-- Health protection precautions
-- Environmental Protection
- LIFTING AND JACKING
-- Safety
- JACKING POINTS
- LIFTING
-- Workshop Hoist
-- Workshop Jack
-- Stands
- VEHICLE RECOVERY
-- General
-- Transporting
-- Suspended Towing
-- Adhere to Towing Regulations
-- Towing by Another Vehicle
- VEHICLE IDENTIFICATION NUMBER
-- VIN Number Location
-- Engine Number
-- Gearbox Number
01-00 BODY SYSTEM
- BODY STRUCTURE (01.01)
-- Overview
-- Specifications
-- Maintenance
-- Right Side Front Crush Bar for the Body Reinforcement - Remove and Install
-- Left Side Front Crush Bar for the Body Reinforcement - Remove and Install
-- Front Crush Brace - Remove and Install
- FRONT END (01.02)
-- Front Wings
-- Specifications
-- Maintenance
-- Radiator Closing Panel - Remove and Install
-- Centre Undertray - Remove and Install (Roadster Only)
-- Front Undertray-Remove and Install
-- Rear Undertray - Renew (Coupe only)
-- Rear Undertray - Renew (Roadster only)
-- Install
-- Undertray, Vehicle Set - Renew
-- RH/LH Front Wheel Arch Liner - Renew
-- RH/LH Rear Wheel Arch Liner - Renew
-- RH Front Wing Panel Assembly - Renew
-- LH Front Wing Panel Assembly - Renew
- BODY CLOSURES (01.03)
-- Specifications
-- Doors
-- Tailgate
-- Bonnet
-- Maintenance
-- LH/RH Door Assembly-Renew
-- RH/LH Door Assembly-Remove/Refit
-- Front Door Hinge (One Side) - Renew
-- Front Door Check Arm Assembly - Renew
-- Boot Lid Assembly - Renew (Roadster Only)
-- Boot Lid Hinge Assembly (Pair) - Renew (Roadster Only)
-- Boot Gas Strut (Pair) - Renew (Roadster Only)
-- Boot Lid Striker Assembly - Renew (Roadster Only)
-- Exterior Boot Lid Switch Release - Renew (Roadster Only)
-- Tailgate Assembly - Renew
-- Tailgate Hinge Assembly (Pair) - Renew
-- Hood Assembly - Renew
-- Hood Hinge Assembly (Vehicle Set) - Renew
- INTERIOR TRIM (01.05)
-- Maintenance
-- Rear Centre Console - Renew
-- Headlining - Renew (Roadster Only)
-- Header Panel Assembly - Renew (Excluding Roadster)
-- Header Panel Assembly - Renew (Roadster Only)
-- Front Header Console Assembly - Renew
-- RH/LH Upper Rear Pillar Panel Assembly - Renew
-- RH Sun Visor - Renew
-- LH Sun Visor - Renew
-- Door Trimboard Assembly - Renew
-- Door Trimboard Assembly - Remove for Access/Refit
-- Lower Quarter Trim Panel Assembly - Renew (Roadster Only)
-- Side Carpet Kit (RHD) - Renew
-- Side Carpet Kit (LHD) - Renew
-- Top Rear Console Finisher Panel Assembly - Renew (Roadster Only)
-- RH/LH Bodyside Rear Trim Panel Assembly - Renew (Roadster Only)
-- Tonneau to Body Weatherstrip Assembly - Renew (Roadster Only)
-- Door Trim Weather Strip Assembly - Renew (Roadster Only)
- EXTERIOR TRIM (01.08)
-- Maintenance
-- RH/LH Applique Sill - Renew
-- RH Wing Side Strake - Renew
-- LH Wing Side Strake - Renew
-- Channel Assembly Divider Bar - Renew
-- Windshield Header Finisher - Renew (Roadster Only)
- MIRRORS (01.09)
-- Specifications
-- Maintenance
-- RH Door Mirror Assembly - Renew
-- LH Door Mirror Assembly - Renew
- SEATING (01.10)
-- Description
-- Heated Seats
-- Specifications
-- Maintenance
-- RH/LH Front Seat - Remove and Install
-- Front Seat Squab Cover Assembly (Each, Pre-08MY) - Remove and Install
-- Front Seat Squab Cover Assembly (Each, from 08MY) - Remove and Install
-- Front Seat Cushion Cover Assembly (Each)-Renew
-- 6-Way Height Adjuster (Inc. Motors) - Renew
-- Squab Motor Kit - Renew
-- Lumbar Support Kit - Renew
-- Side Airbag - Renew
-- Front Seat Buckle Assembly - Renew
-- Valance Heater and Lumbar Switch Assembly - Renew
-- Seat Harness Kit - Renew
-- RH/LH Seat Switchpack Assembly - Renew
-- Lumbar Pump for the Front Seat (From 08MY) - Remove and Install
-- Lumbar Valve for the Front Seat (From 08MY) - Remove and Install
-- Lumbar Bladder for the Front Seat (From 08MY) - Remove and Install
- GLASS, FRAME AND MECHANISM (01.11)
-- Description
-- Frameless doors
-- Specifications
-- Maintenance
-- Glass Regulator - Renew
-- RH/LH Door Glass - Renew
-- Door Glass - Adjust/Reset
-- Front Windshield - Renew
-- Rear Windshield - Renew
-- Quarter Window Glass - Renew
-- Passenger Window Lift Switch - Renew
-- Driver Window Lift Switch - Renew
- INSTRUMENT PANEL (IP) (01.12)
-- Specifications
-- Maintenance
-- Instrument Panel - Renew
-- Airbag Panel and Door Assembly - Renew
-- Glovebox Assembly - Renew
-- Instrument Centre Panel Assembly - Renew
-- Knee Protector - Renew
-- Instrument Panel Assembly - Renew
-- Cluster Bezel Panel - Renew
-- Driver Panel Assembly - Renew
-- Instrument Panel Bezel Assembly (With Sat. Nav.) - Renew
-- Instrument Panel Bezel Assembly (Without Sat. Nav.) - Renew
-- Rear Console Panel Assembly - Renew
-- Armrest Pad Assembly - Renew
-- Console Panel Assembly - Renew
-- RH/LH Rear Console Panel Assembly - Renew (Roadster Only)
-- Centre Console Panel - Remove and Install (Coupe Only)
-- Centre Console Panel - Remove and Install (Roadster Only)
-- RH/LH Lower Quarter Panel Assembly - Renew (Roadster Only)
- HANDLES AND LOCK MECHANISMS (01.14)
-- Description
-- Vehicle Key/Remote Transmitter
-- Central Locking System
-- Remote Transmitter
-- Fuel Filler Assembly
-- Boot Emergency Release
-- Specifications
-- Maintenance
-- Ignition Cylinder Lock - Renew
-- RH/LH Front Door Latch Assembly - Renew
-- Bonnet Latch Assembly - Renew
-- Hood Release Cable Assembly - Renew (Roadster Only)
-- Bonnet Secondary Latch Assembly - Renew
-- Tailgate Latch and Cable Assembly - Renew
-- Fuel Filler Actuator Assembly - Renew (Roadster Only)
-- Fuel Filler Release Cable - Renew (Roadster Only)
-- Fuel Flap Release Switch - Renew
-- RH/LH Tonneau Latch Motor - Renew (Roadster Only)
-- RH/LH Tonneau Latch - Renew (Roadster Only)
-- RH/LH Tonneau Cover Striker Assembly - Renew (Roadster Only)
-- Tailgate Latch Assembly-Renew (Roadster Only)
- WIPERS AND WASHER SYSTEM (01.16)
-- Headlamp Washing
-- Specifications
-- Maintenance
-- Windscreen Wiper Motor Assembly - Renew
-- Wiper Linkage Assembly - Renew
-- Windshield Wash Tube - Renew
-- Windscreen Reservoir and Motor Assembly - Remove and Install
-- Low Level Water Sensor - Remove and Install
-- Headlamp Wash Motor and Pump Assembly - Renew
-- Headlamp Wash Tube Assembly - Renew
-- Washer Fluid Reservoir - Renew
- CONVERTIBLE ROOF AND ROOF OPENING SUBSYSTEM (01.17)
-- System Description
-- Maintenance
-- Hood Assembly-Renew
-- Canopy Cover - Renew
-- Header Latch Motor - Renew
-- Hydraulic Main Actuator Cylinder - Renew
-- Hydraulic Tensrod Cylinder - Renew
-- Hydraulic Tonneau Cylinder - Renew
-- Convertible Top ECU - Renew
-- Hydraulic Pump - Renew
-- Hydraulic Lock Valve - Renew
-- RH/LH Front Cantrail Seal - Spare Part - Renew
-- RH/LH Front Cantrail Seal Spare Part Kit - Renew
-- RH/LH Middle Cantrail Seal Spare Part - Renew
-- RH/LH Middle Cantrail Seal Spare Part Kit - Renew
-- Rear Seal Spare Part Assembly Kit - Renew
-- LH Fully Automatic Latching Kit - Renew
-- RH Fully Automatic Latching Kit - Renew
-- Convertible Roof Hydraulic Pump - Check Fluid Level
-- Cantrail Cover Trim - Renew
-- B-Post Trim Cover - Renew
-- Tonneau Cover - Renew
-- LH Front Main Hydraulic Cylinder Pipe - Renew
-- LH Rear Main Hydraulic Cylinder Pipe - Renew
-- RH Front Main Hydraulic Cylinder Pipe - Renew
-- RH Rear Main Hydraulic Cylinder Pipe - Renew
-- LH Front Hydraulic Cylinder Pipe - Renew
-- LH Rear Hydraulic Cylinder Pipe - Renew
-- RH Front Hydraulic Cylinder Pipe - Renew
-- RH Rear Hydraulic Cylinder Pipe - Renew
-- RH/LH Rear Hydraulic Tonneau Cylinder Pipe - Renew
-- LH/RH Front Hydraulic Tonneau Cylinder Pipe - Renew
-- Hydraulic Cylinder Valve to Pump Pipe - Renew
-- Wind Deflector - Renew
-- Tonneau Well Liner - Renew
-- RH/LH Flex Shaft - Renew
- BUMPERS (01.19)
-- Front Bumper
-- Rear Bumper
-- Specifications
-- Maintenance
-- Front Bumper Cover - Renew
-- Rear Bumper Cover - Renew
- RESTRAINING DEVICES (01.20)
-- Seat Belts
-- Emergency Locking Retractor (ELR)
-- Airbag System
-- Maintenance
-- Driver’s Airbag Module - Renew
-- LH Front Seat Belt - Renew
-- RH Front Seat Belt - Renew
-- Passenger Airbag - Renew
-- ARS Side Impact Sensor Assembly - B Pillar-Renew
-- Side Impact Door ARS Sensor Assembly - Renew
-- Front Impact Sensor Assembly - Renew
-- Occupant Restraint Control Module Assembly - Renew
-- RH/LH Roll Over Protection System - Renew
02-00 FRAME AND MOUNTINGS
- SUBFRAMES (02.03)
-- Specifications
-- Maintenance
-- Front Subframe-Renew
-- Front Subframe-Remove/Refit
-- Rear Subframe-Renew
-- Rear Subframe-Remove/Refit
-- RH/LH Transmission Rear Hydromount Isolator Assembly-Renew
-- RH/LH Engine Bracket-Renew
-- Engine Hydromount Isolator Assembly- Renew
03-00 ENGINE SYSTEM
- ENGINE ASSEMBLY (03.00)
-- Description
-- Maintenance
-- Engine Assembly-Renew
-- Engine Assembly-Remove for Access and Refit
- ENGINE STRUCTURE (03.01)
-- Engine Block
-- Cylinder Block Drain Plug
-- Knock Sensors
-- Bedplate
-- Engine Mountings
-- Cylinder Heads
-- Inlet/Exhaust Manifolds
-- Specifications
-- Maintenance
-- Upper Intake Manifold Assembly (LHD) - Renew
-- Upper Intake Manifold Assembly (RHD) - Renew
-- Upper Intake Manifold Assembly Gasket (LHD) - Renew
-- Upper Intake Manifold Assembly Gasket (RHD) - Renew
-- Intake Manifold Assembly - Remove for Access and Refit (With Engine Removed)
-- RH/LH Cylinder Head Gasket - Renew
-- RH/LH Cylinder Head - Overhaul
-- Cylinder Head (Engine Set) - Overhaul
-- Valve Set (Engine Set) - Renew (including de-coke)
-- Inlet Valve (Set) - Renew
-- Exhaust Valve (Set) - Renew
-- Spring (Valve Set) - Renew
-- Spring (Inlet Valve Set) - Renew
-- Inlet and Exhaust Valve Seal (Engine Set) - Renew
-- Spring (Valve Exhaust Set) - Renew
-- RH/LH Cylinder Head Gasket - Renew (with Engine Removed)
-- Cylinder Head Gasket (Engine Set) - Renew (with Engine Removed)
-- Description
- LUBRICATION SYSTEM (03.02)
-- Dry Sump System
-- Specifications
-- Engine Oil Specification
-- Maintenance
-- Oil Pressure Pump to Sump Gasket - Renew
-- Oil Pump Chain - Renew
-- Oil Sump Pan - Renew
-- Oil Sump Pan - Remove and Reseal
-- Oil Cooler - Renew
-- Oil Cooler Tank Assembly - Renew
-- Thermostat - Renew
-- Oil Cooler Tank Pipe Assembly - Renew
-- Oil Thermostat to Tank Tube Assembly - Renew
-- Oil Pump Inlet Tube Assembly - Renew
-- Oil Pump Inlet Tube Assembly - Renew
-- Oil Pump Outlet Tube Assembly - Renew
-- Oil Thermostat Cooler Pipe Assembly - Renew
-- Oil Temperature Controller - Renew
-- Oil Sump Pan - Renew (with Engine Removed)
-- Oil Sump Pan - Remove and Reseal (with Engine Removed)
- COOLING SYSTEM (03.03)
-- Description
-- Water Pump
-- Thermostat
-- Radiator
-- Cooling Fans
-- Coolant Reservoir
-- Engine Oil Cooler
-- Specifications
-- Torque Figures
-- Maintenance
-- Coolant-Drain/Fill
-- Thermostat - Renew
-- Water Pump - Renew
-- Water Pump Pulley - Renew
-- Oil Temperature Controller - Renew
-- Radiator Fan and Motor Assembly - Remove and Install
-- Radiator and Condenser Assembly - Renew
-- Radiator Assembly - Renew
-- Air Conditioning Condenser - Renew
-- Radiator Fan Modulator - Remove and Install
-- Expansion Tank Assembly - Renew
-- Coolant Recovery Tank Assembly - Remove and Install
-- Engine Coolant Reservoir Hose - Renew
-- Water Inlet/Outlet Manifold - Renew
-- Engine Electric Coolant Temperature Sensor - Renew
-- Thermostat Cover - Renew
- FUEL CHARGING SYSTEM (03.04)
-- Safety Precautions
-- Maintenance
-- Fuel Rails - Renew
-- Fuel Injection Pressure Sensor - Renew
-- Fuel Temperature Sensor - Renew
-- Fuel Injector Engine Set - Renew
-- Fuel Injector - Each - LH Bank - Renew
-- Fuel Injector - Each - RH Bank - Renew
-- Engine Set - Fuel Injector - LH Bank - Renew
-- Engine Set - Fuel Injector - RH Bank - Renew
- ACCESSORY DRIVE SYSTEM (03.05)
-- Specifications
-- Maintenance
-- Drive Belt-Renew
-- Engine Drive Belt and Bracket Assembly Oil Pump Tensioner-Renew
-- Idler Pulley-Renew
-- Engine Drive Belt Idler Assembly-Renew
-- Description
-- Auxiliary Drives
-- Automatic Belt Tensioner
- ENGINE CRANKING SYSTEM (03.06)
-- Maintenance
-- Starter Motor-Renew
- IGNITION SYSTEM (03.07)
-- Maintenance
-- Coil Assembly-Engine Set - LH-Renew
- EMISSION CONTROL (03.08)
-- Maintenance
-- Vacuum Outlet Hose Assembly-Renew
-- Secondary Air Injection Pump Tube-Renew
-- Vacuum System Reservoir and Bracket Assembly-Renew
-- Oil Tank Breather Hose-Renew
-- Air Cleaner to Rocker Cover Hose-Renew
-- Oil Separator Tube Assembly-Renew
-- Oil Separator Assembly-Renew
-- Emissions Separator Hose-Renew
-- Secondary Air Injection Pump and Bracket Assembly-Renew
-- PCV Valve Assembly-Renew
-- Crank Vent Hose-Renew
-- Exhaust Valve to Exhaust Manifold Tube Assembly-Renew
-- Oil Separator to Inlet Manifold Hose- Renew
-- EGR Module-Renew
- VALVE TRAIN (03.09)
-- Specifications
-- Maintenance
-- Left Side Timing Chain Arm Assembly - Remove and Install
-- Right Side Timing Chain Arm Assembly - Remove and Install
-- RH/LH Secondary Tensioner Assembly - Remove and Install
-- Right and Left Intake Camshaft - Remove and Install
-- Right and Left Exhaust Camshaft - Remove and Install
-- RH/LH Secondary Timing Chain-Renew
-- RH/LH Secondary Tensioner Assembly- Renew (with Engine Removed)
-- RH/LH Intake Camshaft Renew With Engine Removed
-- RH/LH Exhaust Camshaft-Renew (with Engine Removed)
-- RH/LH Secondary Timing Chain-Renew (with Engine Removed)
-- RH/LH Intake Camshaft Sprocket and Housing Assembly-Renew
-- Left Side Primary Chain - Remove and Install)
-- RH/LH Intake Camshaft Sprocket and Housing Assembly-Renew (with Engine Removed)
- ENGINE SEALING (03.10)
-- Specifications
-- Maintenance
-- Engine Timing Cover - Renew
-- Left Side Cam Cover - Remove and Install
-- Left Side Cam Cover Gasket - Renew
-- Right Side Cam Cover Gasket - Renew
-- Cylinder Head Gasket - Renew (Engine Set)
-- Right Side Cam Cover - Remove and Install
-- Cam Cover - Vehicle Set - Remove and Install
-- Engine Timing Cover-Renew (with Engine Removed)
-- John Guest Cartridge in the Engine Timing Cover - Repair
- POWER CONVERSION (03.11)
-- Maintenance
-- Connecting Rod Bearing-Renew (Engine Set)
-- Crankshaft Main Bearing-Renew (Engine Set)
-- Crankshaft Assembly-Renew
-- Piston-Renew (Engine Set)
-- Piston-Renew
-- Additional Piston-Renew (Each)
-- Piston Ring-Renew (Engine Set)
-- Piston Ring-One Piston Set-Renew
-- Piston Ring Set-Additional-Renew (Each)
-- Connecting Rod-Renew (Engine Set)
-- Crankshaft Damper Pulley Assembly- Renew
-- Crankshaft Front Oil Seal-Renew
-- Rear Oil Crankshaft Seal-Renew
-- Cylinder Block-Renew
-- Crankshaft Damper Pulley Assembly- Renew (with Engine Removed)
-- Crankshaft Front Oil Seal-Renew (with Engine Removed)
-- Crankshaft Rear Oil Seal-Renew (with Engine Removed)
- AIR CHARGING (03.12)
-- Maintenance
-- Clean Air Duct - Remove and Install
-- Engine Air Filter - Remove and Install
- EVAPORATIVE EMISSIONS (03.13)
-- Description
-- System Operation
- ENGINE MANAGEMENT SYSTEM (03.14)
-- Maintenance
-- Right Engine Control Module - Renew
-- LH Front Lower Heated Exhaust Gas Oxygen (HEGO) Sensor - Renew
-- LH Front Upper Heated Exhaust Gas Oxygen (HEGO) Sensor - Renew
-- RH Front Upper Heated Exhaust Gas Oxygen (HEGO) Sensor - Renew
-- RH Rear Lower Heated Exhaust Gas Oxygen (HEGO) Sensor - Renew
-- Left Side Powertrain Control Module (PCM) (Coupe Only) - Remove and Install
-- Left Side Powertrain Control Module (PCM) (Roadster Only) - Remove and Install
- THROTTLE CONTROL (03.16)
-- Description
-- Motorised Throttles
- FOOT OPERATED CONTROL (03.18)
-- Maintenance
-- Throttle Pedal Assembly-Renew
04-00 SUSPENSION
- ROAD WHEEL ALIGNMENT (04.00)
-- Specifications
-- Maintenance
-- All Wheel Alignment
- FRONT SUSPENSION (04.01)
-- Description
-- Suspension Arms
-- Anti-roll Bar
-- Vertical link
-- Specifications
-- Symptoms
-- Maintenance
-- RH/LH Front Hub and Bearing Assembly - Renew
-- RH/LH Lower Front Suspension Arm Assembly - Renew
-- RH/LH Upper Front Suspension Arm Assembly - Renew
-- Front Anti-Roll Bar - Renew
-- Front Pair Anti-Roll Bar Bushing - Renew
-- RH/LH Front Anti-Roll Bar Link - Renew
-- RH/LH Front Hub Vertical Link - Renew
-- Front Suspension Sensor Assembly- Renew
- REAR SUSPENSION (04.02)
-- Description
-- Suspension Arms
-- Anti-roll Bar
-- Vertical Link
-- Specifications
-- Maintenance
-- RH/LH Rear Hub and Bearing Assembly- Renew
-- RH/LH Rear Lower Arm Assembly-Renew
-- RH/LH Upper Rear Arm Assembly-Renew
-- RH/LH Toe Control Rear Arm Assembly- Renew
-- Rear Anti-Roll Bar-Renew
-- Rear Pair-Anti-Roll Bar Bushing-Renew
-- RH/LH Rear Anti-Roll Bar Link-Renew
-- RH/LH Rear Hub Vertical Link-Renew
-- Rear Suspension Sensor Assembly- Renew
- SHOCK ABSORBER SYSTEM (04.03)
-- Description
-- Specifications
-- Maintenance
-- Front Spring and Damper Assembly-Pair- Renew
-- Front Spring-Pair-Renew
-- Front Damper-Pair-Renew
-- Rear Spring and Damper Assembly-Pair- Renew
-- Rear Spring-Pair-Renew
-- Rear Damper-Pair-Renew
- ROAD WHEELS AND TYRES (04.04)
-- Specifications
-- USA Tyre Gradings
-- Tread Wear
-- Traction
-- Temperature
-- Maintenance
-- Safety
-- Tyre Replacement and Wheel Interchanging
-- Winter (Snow) tyres
-- Recommended Winter Wheel and Tyre Combination
-- Inspection and Verification
-- Tyre Wear
-- Tyre Damage
-- Repairs
-- Care of Alloy Road Wheels
-- Road Wheel Alignment
-- Road Wheel and Tyre Balance
-- Torque Tightening of Road Wheel Nuts
-- Tyre Pressure Sensing (Option)
-- Pressure Sensing with Winter Wheels and Tyres
-- Warnings
-- Display Unit
-- System Programming
05-00 DRIVELINE
- DRIVESHAFT (05.01)
-- Description
-- Specifications
-- Maintenance
-- Propeller Shaft-Renew
-- Propshaft Cam Sensor-Sportshift-Renew- Sportshift Only
-- Torque Tube-Renew
-- Torque Tube & Prop Shaft Assembly- Renew-Manual Vehicles Only
-- Torque Tube & Prop Shaft Assembly- Renew-Sportshift Vehicles Only
-- Torque Tube-Remove for Access/Refit
-- RH/LH Drive Shaft Assembly-Renew
- HALFSHAFTS (05.05)
-- Specifications
07-00 TRANSMISSION
- TRANSMISSION COOLING (07.02)
-- Specifications
-- Maintenance
-- Oil Cooler Matrix-Renew
-- Manual Transmission Oil Outlet Hose- Renew
-- Manual Transmission Oil Inlet Hose- Renew
- MANUAL TRANSMISSION (07.03)
-- Description
-- Cooling
-- Specifications
-- Maintenance
-- Transaxle Assembly - Remove for Access and Install
-- Complete Sportshift Hydraulic Kit-Renew
-- Complete Shifter Assembly-Renew- Roadster Only
-- Reservoir Tank Assembly-Renew- Roadster Only
-- Pump Inlet/Valve Body Bleed/Reservoir Tank Hoses-Renew-Roadster Only
-- Hydraulic Pump Assembly-Renew- Sportshift Only
-- HP Hose Kit-Renew-Roadster Only
-- Dry Break Connector-Renew-Roadster Only
-- Clutch Position Sensor-Renew-Roadster/ Sportshift Only
-- Transmission Sensor Assembly-Renew- Sportshift Only
-- Transmission Valve Block-Renew
-- Shifter Assembly Gasket-Renew
-- Transaxle Assembly - Sportshift Only - Remove for Access & Install
-- Transmission Axle Assembly-Drain/Refill
-- Transaxle Assembly-Renew
- AUTOMATIC CONTROL SYSTEM (07.05)
-- Maintenance
-- Paddle Shift Switch Assembly - Renew - (Sportshift Only)
-- Sportshift Drive Switch-Renew-Sportshift Only
-- Sportshift Neutral Switch-Renew- Sportshift Only
-- Sportshift Reverse Switch-Renew- Sportshift Only
-- Sportshift Comfort Switch-Renew- Sportshift Only
-- Sportshift Interface Box-Renew- Sportshift Only
- MANUAL CONTROL SYSTEM (07.06)
-- Maintenance
-- Gearshift Assembly Mechanism-Renew
-- Transmission Gearshift Cable Assembly- Renew
- AUTOMATIC SHIFTING SUBSYSTEM (07.11)
-- Maintenance
-- Transmission Control Module-Renew- Sportshift Only
06-00 BRAKE SYSTEM
- FRONT DISC BRAKE (06.03)
-- Description
-- Specifications
-- Maintenance
-- Front Brake Disc Set - Renew
-- Front Caliper-Renew
-- Front Pad Kit - Renew
-- Front Brake Hose Assembly - Renew
- REAR DISC BRAKES (06.04)
-- Description
-- Specifications
-- Maintenance
-- Rear Brake Disc Set-Renew
-- RH/LH Rear Caliper-Renew
-- Rear Pad Kit-Renew
-- Rear Brake Hose Assembly-Renew
- HAND BRAKE (06.05)
-- Description
-- Specifications
-- Maintenance
-- RH/LH Handbrake Caliper-Renew
-- Handbrake Lever Assembly-Renew
-- Handbrake Pad Set-Renew
-- Handbrake Cable Assembly-Adjust
-- Handbrake Cable Assembly-Vehicle Set- Renew
- BRAKE ACTUATION SYSTEM (06.06)
-- Description
-- Tandem Master Cylinder
-- Specifications
-- Maintenance
-- Pedal Box Assembly - Renew
-- Installation
-- RHD-Brake Master Cylinder Assembly- Renew
-- LHD-Brake Master Cylinder Assembly- Renew
-- Clutch Master Cylinder Assembly-Renew
-- RH/LH Front Caliper Hose Assembly- Renew
-- RH/LH Rear Brake Caliper Tube Assembly-Renew
-- Brake Master Cylinder to Modulator Secondary Tube Assembly-Renew
-- Brake Master Cylinder to Modulator Primary Tube Assembly-Renew
-- Rear Wheel Brake Front to Rear Tube Assembly-Renew
-- RH Front Caliper to Modulator Tube Assembly-Renew
-- Rear Wheel Brake Tube Assembly-Renew
-- Dynamic Stability Control Module- Renew
- POWER BRAKE SYSTEM (06.07)
-- Brake Booster
-- Emergency Brake Assist
-- Specifications
-- Maintenance
-- Brake Booster-RHD-Renew
-- Brake Booster-LHD-Renew
-- Brake Fluid Reservoir-Renew
-- Brake Bleeding - AMDS
-- Brake Master Cylinder and Vacuum Booster-Renew
-- Brake Master Cylinder-Renew
- ANTI-LOCK BRAKING SYSTEM (ABS) (06.09)
-- Dynamic Stability Control
-- Concept
-- System Overview
-- Operation Summary
-- Traction Control
-- Functional Description
-- Engine Intervention
-- Brake Intervention
-- ABS / DSC Circuit
-- Specifications
-- Maintenance
-- ABS Modulator - Remove and Install
08-00 CLUTCH
- CLUTCH ASSEMBLY (08.01)
-- Description
-- Specifications
-- Maintenance
-- Clutch and Flywheel Assembly-Renew
-- Slave Clutch Cylinder-Renew
-- Clutch Bleed Hose Assembly-Renew
-- Clutch Hydraulic System-Bleed- Sportshift Only
-- Clutch Hydraulic System-Bleed
-- Master Cylinder to Slave Cylinder Tube Assembly-Renew-Sportshift Only
09-00 EXHAUST
- EXHAUST OVERVIEW
- SILENCER ASSEMBLY (09.01)
-- Variable Flow Silencer Assembly
-- Maintenance
-- LH Catalyst & Pipe Assembly-Renew
-- RH Catalyst & Pipe Assembly-Renew
-- LH Exhaust Manifold-Renew-Roadster Only
-- Heated Exhaust Gas Oxygen (HEGO) Sensor - Remove and Install
-- Silencer and Bypass Valve Assembly- Remove for Access/Refit-Coupe Only
-- Silencer and Bypass Valve Assembly- Remove for Access/Refit-Roadster Only
-- Silencer and Bypass Valve Assembly- Renew
-- Exhaust Rear Silencer Mounting Rubber- Renew
-- Exhaust System-Renew
-- Exhaust System (Excluding Manifold/ Downpipes)-Renew
- PIPES AND SUPPORTS (09.03)
-- Specifications
-- Maintenance
-- RH/LH Catalyst and Pipe Assembly- Renew
-- Exhaust Centre Pipe-Renew
-- RH Exhaust Manifold-Renew
-- LH Exhaust Manifold-Renew
-- RH Exhaust Manifold Gasket-Renew
-- LH Exhaust Manifold Gasket-Renew
-- Exhaust Gas Temperature Sensor-Renew
-- RH/LH Rear Exhaust Pipe Assembly- Renew
10-00 FUEL
- FUEL TANK AND LINES (10.01)
-- Description
-- Fuel Tank
-- Fuel Pumps
-- Jet Pumps
-- Filler Neck and Check Valve
-- Valves and Sensors
-- Fuel System Schematic
-- Evaporative Loss System
-- System Operation
-- Fuel Tank Vents and Control Valves
-- Safety Precautions
-- Specifications
-- Maintenance
-- Fuel System
-- Fuel Filter Assembly-Renew
-- Fuel Pump and Reservoir Assembly- Renew
-- Fuel Tank and Canister Assembly-Renew
-- Fuel Tank and Canister Assembly- Remove for Access/Refit
-- Fuel Tank Sender Assembly-Renew
-- Fuel Vapour Pipe Assembly-Renew
-- Fuel Supply and Vapour Pipe Assembly- Renew
-- Manifold Supply Fuel Pipe Assembly- Renew
11-00 STEERING
- STEERING GEAR (11.01)
-- Diagnostics - Symptom Chart
-- Specifications
- POWER STEERING (11.02)
-- Description
-- Specifications
-- Maintenance
-- Power Steering System - Bleed
-- Procedure
-- Power Steering Pump-Renew
-- Power Assisted Steering (PAS) Rack - Remove and Install
-- RH/LH Track Rod End-Renew
-- Power Steering Pump to Rack Hose Assembly-Renew
-- Power Steering Rack to Cooler Hose- Renew
- STEERING COLUMN (11.04)
-- Description
-- Specifications
-- Maintenance
-- Top Shroud for the Steering Column - Remove and Install
-- Bottom Shroud for the Steering Column - Remove and Install
-- Steering Column Gaiter-Renew
-- Upper Steering Column Assembly- Renew
-- Top and Bottom Shrouds for the Steering Column - Remove and Install
-- Steering Column Lower Shaft Assembly- Renew
- STEERING COLUMN SWITCHES (11.05)
-- Maintenance
-- Ignition Switch-Renew (Pre-08 MY Only)
-- Steering Column Stalk Assembly Switch- Renew (Pre-08 MY Only)
-- Cruise Control Switch-Renew
-- Indicator Switch for the Steering Column - Remove and Install
-- Airbag Rotary Coupler Assembly - Remove and Install
-- Wiper Switch for the Steering Column - Remove and Install
- STEERING WHEEL (11.06)
-- Specifications
-- Maintenance
-- Steering Wheel-Renew
-- Driver’s Airbag Module - Remove and Install
12-00 CLIMATE CONTROL
- BODY VENTILATION (12.01)
-- Air Intake & Distribution System
-- Air Intake Actuator
-- Air Mix Actuator
-- Airflow Mode Actuator
- HEATER SYSTEM (12.02)
-- Maintenance
-- RHD/LHD Heater Unit (Including ECU)- Renew
- AIR CONDITIONING (A/C) SYSTEM (12.03)
-- Major Components
-- Refrigerant System
-- Storing Refrigerant
-- Handling Insufficient Refrigerant Level
-- Handling Compressor Oil
-- Refrigeration Cycle
-- Specifications
-- Refrigerant and Lubricant
-- Capacities
-- Torque Figures
-- Diagnostics
-- Electrical Connectors
-- DTC Inspection
-- Single Fault Codes
-- Multiple Fault Codes
-- Maintenance
-- Connections
-- Recovery
-- Evacuation
-- Charging
-- A/C System Testing
-- Leaks
-- System Pressure Fault Classification
-- Maintenance
-- Condenser-Renew
-- Air Conditioning Compressor-Renew
-- Blower Assembly-Renew
-- Compressor to Condenser Tube Assembly-Renew
-- Troubleshooting
13-00 INFORMATION, GAUGE AND WARNING
- INSTRUMENT CLUSTER (13.01)
-- Description
-- Information and Warning Lamps
-- DIM Display layout
14-00 POWER SUPPLY
- BATTERY SYSTEM (14.01)
-- Description
-- Battery Connect Switch
-- Battery Disconnection and Alarm Activation
-- Charging Circuit
-- +12 Volt Distribution
-- Specifications
-- Maintenance
-- Battery Disconnect Switch-Renew
-- Battery Conditioner-Renew
-- Battery Disconnect Switch to Bulkhead Stud Cable Assembly-Renew
-- Battery to Battery Disconnect Switch Cable Assembly-Renew
-- Bulkhead to Starter Jump Terminal Harness-Renew
-- BDS to Bulkhead Dirty Feed Harness- Renew
- ALTERNATOR AND REGULATOR SYSTEM (14.02)
-- Description
-- Specifications
-- Maintenance
-- Alternator-Renew
15-00 VEHICLE ENTERTAINMENT
- AUDIO SYSTEM (15.01)
-- Maintenance
-- Power Amplifier-Renew
-- Subwoofer Premium Amplifier-Renew
-- Centre Stack Assembly-Remove for Access/Refit
-- Centre Stack assembly-Renew
-- GPS Tuner-Renew
-- Multi Media Module-Renew
- ANTENNA (15.02)
-- Maintenance
-- GPS Antenna-Renew
-- ICE System Antenna-Renew
16-00 VACUUM DISTRIBUTION
- BODY VACUUM SYSTEM (16.01)
-- Description
17-00 LIGHTING
- FRONT LIGHTS (17.01)
-- Specifications
-- Maintenance
-- RH/LH Headlamp Assembly-Renew
-- Headlamp Alignment-Adjust
-- Front Side Repeater Lamp Assembly - Remove and Install
-- Front Side Repeater Bulb - Remove and Install
- INTERIOR LIGHTING (17.02)
-- Specifications
- REAR LIGHTS (17.03)
-- Specifications
-- Maintenance
-- Licence Plate Illumination Bulb - Remove and Install
- LIGHTING MECHANISMS (17.04)
-- Headlamp Levelling (HID Only)
18-00 ELECTRICAL DISTRIBUTION AND CONTROL
- WIRING AND CIRCUIT PROTECTION (18.01)
-- Fuse Boxes
-- Engine Bay Fuse/Relay Box
-- Central Electronics Module Fusebox
-- How to Read the Circuits
-- Wires
-- Controller Area Network (CAN)
-- Media Oriented System Transport (MOST)
-- Connectors
-- Splices
-- Relays
-- Busbars
-- Fuses
-- Resistors
-- Lamps
-- Switches
-- Motors and Pumps
-- Diodes
-- Transistor
-- Earth / Ground
-- Maintenance
-- Forward Harness-Renew
-- Header Latch Harness-Renew (Roadster Only)
-- Roof Cylinder Wiring Harness-Renew (Roadster Only)
-- Transaxle Harness-Renew
-- Engine Wiring Harness-Renew
-- Facia Harness-Renew
-- Cabin Harness Assembly-Renew
-- Passenger Door Harness-Renew
-- Driver’s Door Harness-Renew
-- Rear Bumper Harness-Renew
-- Transaxle Harness-Renew
-- Axle Transmission Harness-Renew- Sportshift Only
-- Tailgate Harness-Renew
- VEHICLE CONTROL SYSTEM (18.08)
-- Module Configuration
-- Principles of Operation
-- Market Configuration
-- Customer Configuration
-- Data Buses
-- Network Bus
-- MOST
-- Module Locations
19-00 ELECTRONIC FEATURES
- ACTIVE ANTI-THEFT SYSTEM (19.01)
-- Alarm System Overview
-- Component Descriptions
-- Functional Description
-- Overview – Alarm
-- General setting
-- Door open
-- Disable the Alarm
-- Reduced guard mode
-- Alarm Cycle
-- Panic Alarm
-- Remote Transmitter
-- Key Learning Operations
-- Integrated Passive Anti-Theft System (IPATS)
-- Description
-- Disarming IPATS
-- Arming IPATS
-- IPATS LED
-- Key Programming
-- Maintenance
-- Tracker-Renew
-- Mass Movement Sensor-Renew
-- Pats Tranceiver ECU (Pre-08 MY Only) - Remove and Install
-- Hood Latch Switch-Renew
-- Alarm Siren-Renew
- ELECTRONIC FEATURES MODULES (19.05)
-- Maintenance
-- Electronic Passenger Door Module- Renew
-- Electronic Driver’s Door Module-Renew
20-00 APPENDIX AND GLOSSARY.PDF
- DIAGNOSTIC PORTS (20.01)
- FLUIDS/CAPACITIES
-- Terms
- SPECIAL TOOLS
- MAINTENANCE SCHEDULES
- TORQUE FIGURES
-- General Torque Figures
-- Vehicle Torque Figures Torque Conversion Tables