Aston Martin DB9 Instruction manual

Workshop Manual
Issue 7

Aston Martin Lagonda Limited
Banbury Road, Gaydon, WARWICK, Warwickshire,
England, MK16 9AN
Telephone: [phone] Fax: [phone]
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 7, September 2010 Part No. 4G43-43-10032

Issue 7, September 2011 Workshop Manual I-I-III
DB9 Workshop Manual
Contents
Introduction
Welcome............................................................... i-i-iv
Safety Precautions................................................... i-i-v
Lifting and Jacking................................................. i-i-vii
Vehicle Recovery ..................................................i-i-viii
Vehicle Identification Number ............................... i-i-ix
Body System (01.00)
Body Structure (01.01)..........................................1-1-3
Front End System (01.02) ......................................1-2-1
Body Closures (01.03)...........................................1-3-1
Interior Trim (01.05) .............................................1-5-1
Exterior Trim (01.08).............................................1-8-1
Mirrors (01.09)......................................................1-9-1
Seating (01.10)....................................................1-10-1
Glass, Frame and Mechanism (01.11)..................1-11-1
Instrument Panel (IP) (01.12)...............................1-12-1
Handles and Lock Mechanisms (01.14) ...............1-14-1
Wipers and Washer System (01.16).....................1-16-1
Bumpers (01.19) .................................................1-19-1
Restraining Devices (01.20).................................1-20-1
Frame and Mounting (02.00)
Subframes (02.03).................................................2-1-2
Engine System (03.00)
Engine Assembly (03.00) .......................................3-0-3
Engine Structure (03.01)........................................3-1-1
Lubrication System (03.02)....................................3-2-1
Cooling System (03.03) .........................................3-3-1
Fuel Charging System (03.04)................................3-4-1
Accessory Drive System (03.05).............................3-5-1
Engine Cranking System (03.06) ............................3-6-1
Ignition System (03.07) .........................................3-7-1
Emission Control (03.08).......................................3-8-1
Valve Train (03.09) ...............................................3-9-1
Engine Sealing (03.10).........................................3-10-1
Power Conversion (03.11)...................................3-11-1
Air Charging (03.12)............................................3-12-1
Evaporative Emissions (03.13) .............................3-13-1
Engine Management System (03.14)....................3-14-1
Throttle Control (03.16) ......................................3-16-1
Suspension (04.00)
Road Wheel Alignment (04.00) .............................4-0-2
Front Suspension (04.01).......................................4-1-1
Rear Suspension (04.02)........................................4-2-1
Road Wheels and Tyres (04.04) ............................4-4-1
Driveline (05.00)
Driveshaft (05.01) .................................................5-1-2
Rear Drive System (05.02) ....................................5-2-1
Halfshafts (05.05)..................................................5-5-1
Brake System (06.00)
Description...........................................................6-1-2
Front Disc Brake (06.03) .......................................6-3-1
Rear Disc Brakes (06.04).......................................6-4-1
Hand Brake (06.05) ..............................................6-5-1
Brake Actuation System (06.06) ............................6-6-1
Power Brake System (06.09) .................................6-9-1
Transmission (07.00)
Automatic Transmission (07.01) ............................7-1-2
Transmission Cooling (07.02) ................................7-2-1
Manual Transmission (07.03) ................................7-3-1
Automatic Control System (07.05).........................7-5-1
Clutch (08.00)
Clutch Controls (08.02).........................................8-2-1
Exhaust (09.00)
Exhaust Overview .................................................9-1-2
Silencer Assembly (09.01) .....................................9-1-3
Pipes and Supports (09.03) ...................................9-3-1
Fuel (10.00)
Fuel Tank and Lines (10.01)................................10-1-2
Steering (11.00)
Steering Gear (11.01)..........................................11-1-2
Power Steering (11.02)........................................11-2-1
Steering Column (11.04).....................................11-4-1
Steering Column Switches (11.05).......................11-5-1
Steering Wheel (11.06) .......................................11-6-1
Climate Control (12.00)
Body Ventilation system (12.01)..........................12-1-3
Heater System (12.02) ........................................12-2-1
Air Conditioning (A/C) System (12.03) .................12-3-1
A/C Control System (12.04).................................12-4-1
Information, Gauge and Warning (13.00)
Instrument Cluster (13.01) ..................................13-1-2
Power Supply (14.00)
Battery System (14.01) ........................................14-1-2
Alternator and Regulator System (14.02) .............14-2-1

I-I-IV Workshop Manual Issue 7, September 2011
Vehicle Entertainment (15.00)
Audio System ..................................................... 15-1-1
Vacuum Distribution (16.00)
Body Vacuum System (16.01)............................. 16-1-1
Lighting (17.00)
Front Lights (17.01) ............................................ 17-1-2
Interior Lighting (17.02)...................................... 17-2-1
Rear Lights (17.03) ............................................. 17-3-1
Lighting Mechanisms (17.04) .............................. 17-4-1
Electric Distribution/Electronic Control (18.00)
Wiring and Circuit Protection (18.01) ................. 18-1-2
Vehicle Control System (18.08) .......................... 18-8-1
Electronic Features (19.00)
Active Anti-Theft System (19.01)......................... 19-1-2
Navigation (19.07).............................................. 19-7-1
Appendix & Glossary
Diagnostic Ports................................................... 20-1-2
Fluids/Capacities.................................................. 20-1-3
Abbreviations ...................................................... 20-1-3
Terms.................................................................. 20-1-3
Special Tools - Pictorial Index.............................. 20-1-4
Specialist Tool Operation .................................... 20-1-8
Maintenance Schedules..................................... 20-1-11
Torque Figures .................................................. 20-1-14
Torque Conversion Tables ................................. 20-1-31

Issue 7, September 2011 Workshop Manual I-I-V
Introduction
Contents
Welcome................................................................ I-I-VI
Chapters ................................................................ I-VI
Chapter Navigation ................................................I-VI
Numbering ............................................................ I-VI
Special Tools.......................................................... I-VI
Location References............................................... I-VI
Warnings, Cautions and Notes.............................. I-VI
Repairs and Replacements .................................... I-VI
Safety Precautions ................................................I-I-VII
Battery Disconnection .......................................... I-VII
Air Conditioning (A/C) System.............................. I-VII
Chemical Handling and Storage........................... I-VII
Electrical Equipment............................................. I-VII
Exhaust Fumes..................................................... I-VIII
Fire Precautions................................................... I-VIII
Tools and Equipment........................................... I-VIII
Used Engine Oil..................................................... I-IX
Health Protection Precautions............................... I-IX
Environmental Protection...................................... I-IX
Lifting and Jacking ................................................. I-I-IX
Safety ..................................................................... I-IX
Jacking Points ........................................................ I-IX
Stands.................................................................. I-X
Workshop Hoist.......................................................I-X
Vehicle Recovery..................................................... I-I-X
General....................................................................I-X
Transporting ............................................................I-X
Suspended Towing..................................................I-X
Front Suspended Tow........................................... I-X
Rear Suspended Tow........................................... I-XI
Towing an Automatic Vehicle.................................I-XI
Towing Regulations................................................I-XI
Towing by Another Vehicle....................................I-XI
Push-start............................................................... I-XI
Identification Numbers ........................................I-I-XII
Vehicle Identification Number (VIN).................... I-XII
VIN Number Location...........................................I-XII
Engine Number.................................................... I-XIII
Gearbox Number................................................. I-XIII
Automatic Gearbox..............................................I-XIII
Manual Gearbox..................................................I-XIII

Welcome
Introduction
I-I-VI Workshop Manual Issue 7, September 2011
Introduction
Welcome
This Workshop Manual is part of a suite of technical manuals
provided for DB9. Other technical manuals include:
• Parts manual
• OBDII Diagnostic manual
• Man hour schedules
Chapters
The DB9 suite of manuals incorporate a new chapter
structure.
Each chapter in this workshop manual is associated with a 4
digit number, i.e. Transmission (07.00). Each chapter is then
further broken into sections, i.e. Automatic Transmission
(07.01).
Chapter Navigation
Example 1:
Previous workshop manuals would have Steering and
Suspension together in one chapter. The new structure now
places Steering and Suspension into their own chapters.
Road wheels are also now included in Suspension.
Example 2:
Fuel, emissions and exhaust is now in three different
chapters. Fuel has its own chapter and includes all fuel
aspects up to the fuel rails (Fuel rails and fuel injection now
come under Engine System). Exhaust, not including
manifolds, has its own chapter and Emissions now come
under the Engine system.
When required references are made out to other chapters.
Numbering
Chapters and sections within chapters are numbered using
the system detailed above. All technical manuals for this
vehicle use the same numbering system. When carrying out
a procedure, the relevant parts illustration and spare parts list
can be found using the same numbering system.
To avoid excessive repetition, each procedure is fully
detailed once in its appropriate chapter. In any other
location where this procedure is required, it is referenced by
its title and chapter / page number.
Special Tools
Where special service tools are required to perform an
operation, the tool number is recorded at the point of use
within the procedure. Where the operation of a special
service tool is complicated or not obvious, refer to the
Appendix and Glossary for detailed operation procedures. A
pictorial list of special service tools available for this vehicle
can also be found in the Appendix and Glossary.
Location References
References to left, right, front or
rear of the vehicle or of a
component are referenced from
sitting in the drivers seat facing
forward. Any such references to
assemblies removed from the
vehicle are to the normal
orientation of the assembly when
installed in the vehicle.
Warnings, Cautions
and Notes
The following Warnings, Cautions
and Notes are used within this workshop manual to call your
attention to specific types of information.
Warnings
Cautions
Notes
Repairs and Replacements
Where replacement parts are required, it is essential that
only genuine Aston Martin parts are used. Your attention is
drawn to the following points concerning repairs and the
fitting of genuine Aston Martin parts and accessories:
• Safety features embodied in the vehicle may be impaired
if other than genuine Aston Martin parts are installed. In
certain territories, legislation prohibits the installation of
parts which are not produced to the manufacturers
specification
• Adhere to torque wrench settings given in this manual
• Locking devices, where specified, must be installed. If the
efficiency of a locking device is impaired during removal,
it must be renewed
• The vehicle warranty may be invalidated by the
installation of other than genuine Aston Martin parts
03. 02.
System, i.e. Engine system
Subsystem, i.e. Engine lubrication system
WARNING
INJURY OR DEATH TO PERSONNEL IS POSSIBLE IF
YOU DO NOT OBEY THE INSTRUCTIONS.
CAUTION
DAMAGE TO THE VEHICLE, EQUIPMENT OR TOOLS IS
POSSIBLE IF YOU DO NOT OBEY THE INSTRUCTIONS.
Note: To give information that will help you do the
procedure.

Safety Precautions
Introduction
Issue 7, September 2011 Workshop Manual I-I-VII
Safety Precautions
All service workshops are a source of potential danger and
repair work should only be performed by technically trained
staff following procedures detailed in this manual. A safety
conscious approach to the performance of all service
procedures must be observed at all times. Statutory
requirements governing all aspects of health and safety at
work including directives for the proper use of materials and
equipment must be implemented.
The following headings highlight particular safety
precautions which should be observed (The list is not
intended to be exhaustive).
Battery Disconnection
Where a procedure requires the vehicle battery to be
physically disconnected (disconnect the vehicle battery
earth (Negative) lead), the following items will have to be
reset or re-learnt on connection:
• Seats memory
•Radio pre-sets
•DTCs will be lost
Air Conditioning (A/C) System
Do not break into the A/C refrigeration system until the
refrigerant has been evacuated using the procedure detailed
in this manual. Do not disconnect any A/C refrigerant system
pipes unless trained and instructed to do so. The refrigerant
used can cause blindness if allowed to contact your eyes.

Safety Precautions
Introduction
I-I-VIII Workshop Manual Issue 7, September 2011
Chemical Handling and Storage
Chemicals used in the servicing of motor vehicles include:
acids, adhesives, antifreeze, brake fluids, coolants, grease,
oil, paint, resin and solvents. Exposure to some chemicals
through direct contact or inhalation can cause injury or
death.
Potential hazards can also be present from the incorrect use,
storage and handling of chemicals. causing a fire risk.
Electrical Equipment
Exhaust Fumes
Engines must only be operated where there is fume
extraction equipment in operation or where there is
adequate ventilation.
WARNING
OBEY ALL HANDLING AND SAFETY INFORMATION
THAT IS ON CONTAINERS AND LABELS.
WARNING
DO NOT STORE CHEMICALS IN CONTAINERS THAT
ARE NOT LABELLED OR NOT CORRECTLY LABELLED.
WARNING
DO NOT LEAVE CONTAINERS OPEN THAT ARE USED
FOR STORING CHEMICALS. THE CHEMICALS CAN BE
SPILLED OR FUMES CAN EVAPORATE THAT CAN BE
INFLAMMABLE OR TOXIC.
WARNING
DO NOT MIX CHEMICALS UNLESS INSTRUCTED TO
DO SO, FOLLOWING MANUFACTURERS GUIDELINES.
WARNING
DO NOT BREATHE IN CHEMICAL MATERIALS TO
IDENTIFY THEM. THEY CAN BE TOXIC.
WARNING
DO NOT USE PETROL, KEROSENE, DIESEL FUEL, GAS
OIL, THINNERS OR SOLVENTS TO CLEAN THE SKIN.
WARNING
DO NOT SPRAY CHEMICALS THAT ARE MADE FROM
SOLVENTS (FOR EXAMPLE: PAINT) IN A CONFINED
AREA. THE WORK AREAS THAT ARE USED FOR THESE
OPERATIONS MUST BE WELL VENTILATED AND FUME
EXTRACTION EQUIPMENT MUST BE USED.
WARNING
CONTAINERS THAT HAVE A CAPACITY MORE THAN
25 LITRES (5 GALLONS) NEED A BUND WALL TO
CONTAIN SPILLAGES.
WARNING
AVOID SPLASHING THE SKIN, EYES AND CLOTHING.
WARNING
MAKE SURE THAT THERE IS SUFFICIENT
VENTILATION WHEN YOU USE VOLATILE
DEGREASING MATERIALS.
WARNING
CLEAN ALL CHEMICALS FROM THE SKIN AND
CLOTHING AS SOON AS POSSIBLE AFTER
CONTAMINATION.
WARNING
PUT ON PROTECTIVE CLOTHING SUCH AS
GOGGLES, NON-POROUS GLOVES AND AN APRON
WHEN YOU WORK WITH BATTERY ACID AND OTHER
CORROSIVE AND TOXIC MATERIALS.
WARNING
DO NOT SMOKE NEAR VOLATILE DEGREASING
AGENTS.
WARNING
FUME EXTRACTION EQUIPMENT MUST BE IN
OPERATION WHEN YOU USE SOLVENTS. FOR
EXAMPLE: TRICHLOROETHANE, WHITE SPIRIT, SBP3,
METHYLENE CHLORIDE, PERCHLOROETHYLENE.
WARNING
MAKE SURE THAT ALL ELECTRICAL EQUIPMENT THAT
YOU USE IS IN SAFE WORKING CONDITION BEFORE.
WARNING
INSPECT THE POWER LEADS OF ALL MAINS
ELECTRICAL EQUIPMENT FOR DAMAGE AND
CORRECT INSTALLATION. CHECK THATTHE
EQUIPMENT IS PROPERLY EARTHED WHERE
NECESSARY.
WARNING
MAKE SURE THAT ELECTRICAL EQUIPMENT IS
PROTECTED BY A FUSE OF THE CORRECT CURRENT
RATING.
WARNING
DISCONNECT THE BATTERY BEFORE YOU DO REPAIR
OPERATIONS TO THE ELECTRICAL SYSTEM, FUEL
SYSTEM AND THE ENGINE OR WHEN YOU WORK
BELOW THE VEHICLE.
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 CAN BE FATAL. NEVER
START OR LEAVE THE ENGINE RUNNING IN AN
ENCLOSED AREA THAT IS NOT VENTILATED.
WARNING
DO NOT TOUCH EXHAUST SYSTEM AND ENGINE
COMPONENTS, ENGINE FLUIDS AND ESCAPING
STEAM WITH YOUR SKIN. THEY CAN BE HOT AND
CAUSE BURNS.

Safety Precautions
Introduction
Issue 7, September 2011 Workshop Manual I-I-IX
Fire Precautions
Tools and Equipment
Use the recommended service tool where instructed to do
so.
Used Engine Oil
The workplace should have sufficient washing facilities and
materials to protect the the skin available.
Health Protection Precautions
• Put on protective clothing, including impervious gloves
where possible.
• Do not put oily rags in your pockets.
• Do not get oil on your clothes.
• Clean your work clothes regularly. Discard clothes that
cannot be washed and footwear that is soaked with oil.
• Get First aid treatment immediately for open cuts or
wounds.
• Use barrier creams and apply them before each work
period to help the removal of oil from the skin.
• Wash the skin with soap and water or an approved
cleaner to make sure that all oil is removed. Materials that
contain lanolin will replace the natural skin oils that have
been removed.
• Do not use petrol, kerosene, diesel fuel, gas oil, thinners
or solvents to clean the skin.
• If you get skin problems, get medical help.
• Where possible, degrease all components before you
touch them.
• When there is a risk of eye contact, put on approved eye
protection. There must be an eye-wash station in the work
place.
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. Refer to the local
laws and the environmental department of your Local
Authority for advice about how to correctly discard waste
fluids and materials.
WARNING
MAKE SURE THAT AN APPLICABLE TYPE OF FIRE
EXTINGUISHER IS LOCATED NEAR THE WORK AREA.
WARNING
KEEP OILS, SOLVENTS AND COMBUSTIBLE
MATERIALS AWAY FROM NAKED FLAMES AND OTHER
SOURCES OF IGNITION.
WARNING
PUT NO SMOKING SIGNS ARE NEAR AREAS WHERE
THERE CAN BE COMBUSTIBLE MATERIALS AND
VAPOUR. MAKE SURE THAT THE WARNINGS ARE
STRICTLY OBEYED.
WARNING
MAKE SURE THAT DRY SAND IS AVAILABLE TO
ABSORB SPILLED FUEL OR OTHER FLAMMABLE
MATERIALS.
WARNING
FUME EXTRACTION EQUIPMENT MUST BE IN
OPERATION TO REMOVE COMBUSTIBLE AND TOXIC
FUMES.
WARNING
ALL PERSONNEL MUST KNOW THE FIRE DRILL
PROCEDURES AND SAFETY PRECAUTIONS.
WARNING
DO NOT LEAVE TOOLS, EQUIPMENT OR SPILLED
MATERIALS NEAR OR IN THE WORK AREA.
WARNING
MAKE SURE THAT ALL TOOLS AND EQUIPMENT
THAT YOU USE ARE IN GOOD CONDITION. DO NOT
USE DAMAGED OR DEFECTIVE TOOLS OR
EQUIPMENT.
CAUTION
DO NOT APPLY HEAT TO FREE STIFF NUTS OR
FITTINGS. THIS CAN CAUSE DAMAGE TO PROTECTIVE
COATINGS, ELECTRONIC EQUIPMENT, HARNESSES
AND BRAKE LINES.
WARNING
LONG AND FREQUENT CONTACT WITH USED
ENGINE OILS CAN CAUSE SERIOUS SKIN PROBLEMS
THAT INCLUDE DERMATITIS AND CANCER. PREVENT
TOO MUCH SKIN CONTACTAND WASH FULLY AFTER
CONTACT.
WARNING
OBEY ALL LOCAL LAWS WHEN YOU DISCARD WASTE
OIL AND TOXIC FLUIDS. IF YOU DO NOT, YOU
COULD BE PROSECUTED AND DAMAGE TO THE
ENVIRONMENT CAN OCCUR.
WARNING
LONG AND FREQUENT CONTACT WITH USED
ENGINE OILS CAN CAUSE SERIOUS SKIN PROBLEMS
THAT INCLUDE DERMATITIS AND CANCER. PREVENT
TOO MUCH SKIN CONTACTAND WASH FULLY AFTER
CONTACT.

Lifting and Jacking
Introduction
I-I-X Workshop Manual Issue 7, September 2011
Lifting and Jacking
Safety
Jacking Points
This vehicle jacking points are at positions shown.
The vehicle may also be jacked with the jack placed on the
front subframe, front crossmember.
Always use a jack with a rubber contact pad. Avoid the use
of jacks with sharp contact pads which could damage the
vehicle floor pan Always chock the opposite road wheels as
well as applying the handbrake when using a hydraulic jack.
To prevent body distortion, avoid single point or one side
jacking with the tunnel shear panel removed.
To avoid any danger of bodywork damage when using a
hydraulic jack, the vehicle must only be lifted at the jacking
points.
Stands
When carrying out work (other than a wheel change) which
requires a wheel to be raised, a stand must be used, located
at the jacking point, to provide a secure support for the
vehicle.
Workshop Hoist
Use of a workshop hoist is recommended for all operations
where vehicles must be raised. Follow manufacturers
instructions. If using an adjustable arm type, ensure lifting
pads are correctly positioned at the four jacking points
before lifting.
WARNING
OBEY THE LOCAL WORKSHOP REGULATIONS WHEN
YOU TOW OR LIFT A VEHICLE.
WARNING
DO NOT USE A JACK TO HOLD A VEHICLE WHEN
YOU DO WORK UNDER IT. ALWAYS USE A VEHICLE
LIFT, RAMP OR PIT WHEN YOU WORK UNDER THE
VEHICLE. IF YOU DO NOT, THE JACK CAN COLLAPSE
AND PERSONAL INJURY OR DEATH CAN OCCUR.
WARNING
WHEN YOU WORK UNDER A VEHICLE, CHOCK THE
WHEELS AND APPLY THE HANDBRAKE.
WARNING
MAKE SURE THAT THE VEHICLE IS ON FIRM, LEVEL
GROUND WHEN YOU JACK OR LIFT IT.
WARNING
DO A CHECK THAT THE LIFTING EQUIPMENT HAS
SUFFICIENT CAPACITY FOR THE LOAD BEING LIFTED.
MAKE SURE THAT THE EQUIPMENT IS IN GOOD
WORKING ORDER.
CAUTION
JACK THE VEHICLE ON THE LOWER SUSPENSION
ARMS (FRONT OR REAR).
Front Crossmember

Vehicle Recovery
Introduction
Issue 7, September 2011 Workshop Manual I-I-XI
Vehicle Recovery
General
The preferred method of vehicle recovery is by a flat bed,
covered, transporter.
The towing eye is primarily for emergency use when towing
for short distances, e.g. removing vehicle if it is causing an
obstruction or winching vehicle onto a flatbed transporter.
If moving this vehicle in such a situation, install the towing
eye to the bracket, which is located behind the registration
number plate.
Transporting
If vehicle is to be transported on a trailer or flat bed
transporter the handbrake must be applied and the road
wheels must be chocked.
Suspended Towing
Take care when using 'spectacle frame' type towing
equipment that the towing device is well clear of front or
rear apron. Body damage may occur if vehicle passes over
uneven road surfaces.
Ensure the recovery team follow the following towing
instructions:
Front Suspended Tow
Automatic Transmission Only
1. Switch the ignition ‘On’.
2. Pull back twice on both paddles, simultaneously, to force
the gearbox into ‘Neutral’.
Switch the ignition ‘Off’ within three seconds.
Manual and Automatic Transmissions
3. Remove the ignition key from the ignition.
4. Raise the vehicle using a 'spectacle frame' type lifting
device with a cradle positioned under each front wheel as
indicated below.
Rear Suspended Tow
1. Set the steering in the ‘straight ahead’ position.
2. Remove the ignition key from the ignition. Ensure the
steering is locked in the straight ahead position.
3. Raise the vehicle using a 'spectacle frame' style lifting
device where a cradle is positioned under each rear
wheel as indicated below.
Towing an Automatic Vehicle
Towing Regulations
In some countries, the registration number plate of the
towing vehicle and an “ON TOW” sign or warning triangle
must be shown that can be easily seen at the rear of vehicle
being towed.
Towing by Another Vehicle
The vehicle may be towed for short distances by another
vehicle at speeds of not more than 48 km/h (30 mph). Make
sure that the towed vehicle transmission is in neutral
(manual) or position “N” (automatic), the ignition key turned
to position “II” to release steering lock and to let the horn,
indicators and brake lights operate.
Push-start
Vehicles with automatic transmissions cannot be started by
push-starting.
CAUTION
TAKE CARE TO PROTECT THE PAINT WORK WHEN
INSTALLING THE TOWING EYE. ENSURE THE
TOWING EYE IS TIGHT.
CAUTION
DO NOT TOW WITH ‘SLING’ TYPE EQUIPMENT,
DAMAGE TO BODYWORK WILL RESULT.
CAUTION
A VEHICLE WITH AN AUTOMATIC TRANSMISSION
INSTALLED 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 TRANSMISSION MUST BE SET TO NEUTRAL (N).
IF THE ABOVE SPEED AND DISTANCE LIMITS ARE
EXCEEDED, THE AUTOMATIC TRANSMISSION WILL BE
DAMAGED.
WARNING
THE BRAKE BOOSTER AND THE POWER STEERING
WILL NOT OPERATE WHEN THE ENGINE IS NOT
OPERATING. THE STEERING AND THE BRAKES WILL
NEED MUCH MORE EFFORT TO OPERATE.

Identification Numbers
Introduction
I-I-XII Workshop Manual Issue 7, September 2011
Identification Numbers
Vehicle Identification Number (VIN)
The Vehicle Identification Number (VIN) is a 17 character number which uniquely identifies the vehicle and gives
important data about the build site, date and initial configuration of the vehicle.
VIN Location
The VIN number is stamped / plated in the locations that follow:
Under the bottom edge of the windscreen. At the front of the engine bay.
Stamped on the floorpan in the RH front footwell.
VIN Nu m b er
01-00-004
VIN Nu m b er
01-00-011

Identification Numbers
Introduction
Issue 7, September 2011 Workshop Manual I-I-XIII
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.

Identification Numbers
Introduction
I-I-XIV Workshop Manual Issue 7, September 2011

Issue 7, September 2011 Workshop Manual 1-1-1
Body System (01.00)
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)..............................................1-5-1
Specifications..........................................................5-1
Maintenance...........................................................5-1
IP Trim................................................................... 5-1
Remove............................................................... 5-1
Installation Notes ................................................ 5-1
Roof Trim ..............................................................5-2
Removal.............................................................. 5-2
Installation .......................................................... 5-2
Door Trim.............................................................. 5-3
Removal.............................................................. 5-3
Installation .......................................................... 5-4
Rear Trim...............................................................5-5
Removal (Coupe).................................................5-5
Install (Coupe)..................................................... 5-6
Removal (Volante) ...............................................5-6
Install (Volante) ................................................... 5-6
Boot Trim ..............................................................5-7
Removal.............................................................. 5-7
Installation .......................................................... 5-7
Exterior Trim (01.08) .............................................1-8-1
Maintenance...........................................................8-1
Side Trim...............................................................8-1
Removal.............................................................. 8-1
Installation .......................................................... 8-1
Sill Trim .................................................................8-2
Remove............................................................... 8-2
Installation .......................................................... 8-2
Mirrors (01.09) ......................................................1-9-1
Specifications..........................................................9-1
Maintenance........................................................... 9-1
Door Mirrors.......................................................... 9-1
Removal.............................................................. 9-1
Installation.......................................................... 9-1
Seating (01.10).....................................................1-10-1
Description........................................................... 10-1
Heated Seats ....................................................... 10-1
Seat Module ........................................................ 10-1
Specifications ...................................................... 10-1
Maintenance......................................................... 10-1
Front Seat - Remove and Install............................ 10-1
Remove ............................................................ 10-1
Install................................................................ 10-2
Seat Base Control Motors..................................... 10-2
Front Seat Squab Cover Assembly (Each, from 08MY)
- Remove and Install ............................................ 10-2
Remove ............................................................ 10-2
Install................................................................ 10-2
Seat Module ........................................................ 10-2
Remove ............................................................ 10-2
Install................................................................ 10-2
Seat Module Calibration ...................................... 10-3
Rear Seats............................................................ 10-3
Removal (Coupe) .............................................. 10-3
Installation (Coupe)........................................... 10-3
Removal (Volante) ............................................. 10-4
Installation (Volante).......................................... 10-4
Lumbar Pump for the Front Seat (From 08MY)
- Remove and Install ............................................ 10-4
Remove ............................................................ 10-4
Install................................................................ 10-4
Lumbar Valve for the Front Seat (From 08MY)
- Remove and Install ............................................ 10-4
Remove ............................................................ 10-4
Install................................................................ 10-4
Lumbar Bladder for the Front Seat (From 08MY)
- Remove and Install ............................................ 10-5
Remove ............................................................ 10-5
Install................................................................ 10-5
Glass, Frame and Mechanism (01.11).................1-11-1
Description........................................................... 11-1
Frameless doors ................................................... 11-1
Specifications....................................................... 11-1
Maintenance......................................................... 11-1
Glass Regulator .................................................... 11-1
Removal............................................................ 11-1
Installation........................................................ 11-2
Door Glass........................................................... 11-3
Removal............................................................ 11-3
Installation........................................................ 11-4
Door Glass Setup................................................. 11-6
Rear Quarter Glass (Coupe) ................................. 11-7
Remove ............................................................ 11-7
Installation........................................................ 11-7

1-1-2 Workshop Manual Issue 7, September 2011
Rear Quarter Glass (Volante) ................................11-7
Remove.............................................................11-7
Installation ........................................................11-9
Instrument Panel (IP) (01.12).............................. 1-12-1
Specifications........................................................12-1
Maintenance .........................................................12-1
IP .........................................................................12-1
Removal ............................................................12-1
Installation ........................................................12-3
Veneer Bezel for the Instrument Panel (IP)
- Remove and Install ..........................................12-5
Remove.............................................................12-5
Install ..............................................................12-10
Centre Console Panel - Remove and Install.......12-15
Handles and Lock Mechanisms (01.14).............. 1-14-1
Description ...........................................................14-1
Vehicle Key/Remote Transmitter ..........................14-1
Central Locking System ........................................14-1
Remote Transmitter..............................................14-1
Fuel Filler Assembly..............................................14-1
Manual Boot Release............................................14-1
Boot Emergency Release ......................................14-1
Specifications........................................................14-2
Maintenance .........................................................14-2
Door Handle / Latch Unit.....................................14-2
Removal ............................................................14-2
Installation ........................................................14-3
Wipers and Washer System (01.16).................... 1-16-1
Headlamp Washing ..............................................16-2
Specifications........................................................16-2
Maintenance .........................................................16-2
Driver's Side Wiper Blade - Remove and Install
(12MY onward) ....................................................16-2
Remove.............................................................16-2
Install ................................................................16-3
Passenger’s Side Wiper Blade - Remove
and Install ............................................................16-3
Remove.............................................................16-3
Install ................................................................16-4
Windscreen Reservoir and Motor Assembly
- Remove and Install (12MY onward)....................16-4
Remove.............................................................16-4
Install ................................................................16-4
Low Level Water Sensor - Remove and Install.......16-5
Removal ............................................................16-5
Install ................................................................16-5
Headlamp Wash Motor and Pump Assembly
- Remove and Install.............................................16-5
Remove.............................................................16-5
Install ................................................................16-6
Windscreen Wiper Motor.....................................16-6
Removal ............................................................16-6
Installation ........................................................16-7
Wiper Arms..........................................................16-8
Removal ............................................................16-8
Installation ........................................................16-9
Convertible Roof (01.17)..................................... 1-17-1
Description ...........................................................17-1
Specifications........................................................17-1
Maintenance .........................................................17-2
Roof.....................................................................17-2
Removal............................................................17-2
Installation ........................................................17-2
Roof Material .......................................................17-3
Removal............................................................17-3
Installation ........................................................17-4
Weather Seals ......................................................17-8
Removal............................................................17-8
Installation ........................................................17-8
Roof Pump...........................................................17-8
Removal............................................................17-8
Installation ......................................................17-10
Roof Module......................................................17-11
Removal..........................................................17-11
Installation ......................................................17-11
Roof Lid Hydraulic Rams....................................17-11
Removal..........................................................17-11
Installation ......................................................17-11
Bumpers (01.19) ..................................................1-19-1
Front Bumper........................................................19-1
Specifications.......................................................19-1
Maintenance........................................................19-1
Removal............................................................19-1
Installation ........................................................19-2
Rear Bumper.........................................................19-3
Specifications.......................................................19-3
Maintenance........................................................19-3
Removal............................................................19-3
Installation ........................................................19-5
Restraining Devices (01.20).................................1-20-1
Seat Belts ..............................................................20-1
Pre-tensioner and Load Limiting Systems ............20-1
Emergency Locking Retractor (ELR) .....................20-2
Automatic Locking Retractor (ALR) .....................20-2
Specifications.......................................................20-2
Airbag System .......................................................20-3
Airbag Deployment ..........................................20-3
Dual Inflation Technology..................................20-3
Driver airbag Module.........................................20-3
Passenger Airbag Module...................................20-3
Side Airbag Module ...........................................20-3
Clockspring .......................................................20-3
Restrains Control Module (RCM) ........................20-4
Impact Sensors ..................................................20-4
Specifications........................................................20-4
Maintenance........................................................20-4
Driver Airbag.....................................................20-4
Passenger Airbag................................................20-4
Side Impact Airbag ............................................20-5
Deployable Rollbars .............................................20-6
Specifications.......................................................20-6
Maintenance........................................................20-6
Rollbar Unit.......................................................20-6
Rollbar Sensor ...................................................20-8

Body Structure (01.01)
Body System (01.00)
Issue 7, September 2011 Workshop Manual 1-1-3
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

Body Structure (01.01)
Body System (01.00)
1-1-4 Workshop Manual Issue 7, September 2011

Body Structure (01.01)
Body System (01.00)
Issue 6, March 2010 Workshop Manual 1-1-3
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

Body Structure (01.01)
Body System (01.00)
1-1-4 Workshop Manual Issue 6, March 2010