Aston Martin V8 Vantage Instruction manual

Workshop Manual
Issue 1

Aston Martin Lagonda Limited
Banbury Road, Gaydon, WARWICK, Warwickshire,
England, CV35 0DB
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 1 - October 2005 DVD Part No. 6G43-43-10055

Contents
October 2005 Workshop Manual 0-0-3
V8 Vantage Workshop Manual
Contents
Introduction
Welcome..............................................................0-0-6
Safety Precautions.................................................0-0-7
Lifting and Jacking.................................................0-0-9
Vehicle Recovery ................................................0-0-10
Vehicle Identification Number ............................0-0-11
Body System (01.00)
Body Structure (01.01)..........................................1-1-3
Front End System (01.02) ......................................1-2-1
Body Closures (01.03)...........................................1-3-1
Interior Trim (01.05) .............................................1-4-1
Exterior Trim (01.08).............................................1-5-1
Mirrors (01.09)......................................................1-6-1
Seating (01.10)......................................................1-7-1
Glass, Frame and Mechanism (01.11)....................1-8-1
Instrument Panel (IP) (01.12).................................1-9-1
Handles and Lock Mechanisms (01.14) ...............1-10-1
Wipers and Washer System (01.16).....................1-11-1
Bumpers (01.19) .................................................1-12-1
Restraining Devices (01.20).................................1-13-1
Frame and Mounting (02.00)
Subframes (02.03).................................................2-1-2
Engine Assembly (03.00) .......................................4-3-1
Engine System (03.00)
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) ......................................3-15-1
Suspension (04.00)
Road Wheel Alignment (04.00) .............................4-1-2
Front Suspension (04.01).......................................4-2-1
Rear Suspension (04.02)........................................4-3-1
Road Wheels and Tyres (04.04) ............................4-4-1
Driveline (05.00)
Driveshaft (05.01) .................................................5-1-2
Rear Drive System (05.02).....................................5-2-1
Halfshafts (05.05)..................................................5-3-1
Brake System (06.00)
Description...........................................................6-1-2
Front Disc Brake (06.03) .......................................6-2-1
Rear Disc Brakes (06.04).......................................6-3-1
Hand Brake (06.05) ..............................................6-4-1
Brake Actuation System (06.06) ............................6-5-1
Power Brake System (06.09) .................................6-6-1
Transmission (07.00)
Automatic Transmission (07.01) ............................7-1-2
Transmission Cooling (07.02) ................................7-2-1
Manual Transmission (07.03) ................................7-3-1
Automatic Control System (07.05).........................7-4-1
Clutch (08.00)
Clutch Controls (08.02).........................................8-2-1
Exhaust (09.00)
Exhaust Overview .................................................9-1-2
Silencer Assembly (09.01) .....................................9-1-3
Pipes and Supports (09.03) ...................................9-2-1
Fuel (10.00)
Fuel Tank and Lines (10.01)................................10-1-2
Steering (11.00)
Steering Gear (11.01)..........................................11-1-2
Power Steering (11.02)........................................11-2-1
Steering Column (11.04) .....................................11-3-1
Steering Column Switches (11.05).......................11-4-1
Steering Wheel (11.06) .......................................11-5-1
Climate Control (12.00)
Body Ventilation system (12.01)..........................12-1-3
Heater System (12.02) ........................................12-2-1
Air Conditioning (A/C) System (12.03).................12-3-1
A/C Control System (12.04).................................12-4-1
Information, Gauge and Warning (13.00)
Instrument Cluster (13.01) ..................................13-1-2
Power Supply (14.00)
Battery System (14.01) ........................................14-1-2
Alternator and Regulator System (14.02) .............14-2-1
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

Contents
0-0-4 Workshop Manual October 2005
Electric Distribution/Electronic Control (18.00)
Wiring and Circuit Protection (18.01) ................. 18-1-2
Vehicle Control System (18.08) .......................... 18-2-1
Electronic Features (19.00)
Active Anti-Theft System (19.01)......................... 19-1-2
Appendix & Glossary
Fluids/Capacities................................................. 20-1-2
Abbreviations ..................................................... 20-1-3
Terms................................................................. 20-1-3
Special Tools - Pictorial Index............................. 20-1-4
Specialist Tool Operation ................................... 20-1-6
Maintenance Schedules...................................... 20-1-7
Torque Table...................................................... 20-1-9
Torque Conversion Tables................................ 20-1-10

Contents
October 2005 Workshop Manual 0-0-5
Introduction
Contents .................................................................0-3
Welcome................................................................0-0-6
Chapters .................................................................0-6
Chapter Navigation................................................0-6
Page Numbering.....................................................0-6
Systems Classification Coding................................0-6
Special Tools..........................................................0-0-6
Location References................................................0-6
Warnings, Cautions and Notes..............................0-0-6
Repairs and Replacements .....................................0-6
Safety Precautions .................................................0-0-7
Battery Disconnection ............................................0-7
Air Conditioning (A/C) System................................0-7
Chemical Handling and Storage.............................0-7
Electrical Equipment..............................................0-0-7
Exhaust Fumes........................................................0-7
Fire Precautions......................................................0-7
Tools and Equipment.............................................0-0-8
Used Engine Oil......................................................0-8
Health protection precautions................................0-8
Environmental Protection.......................................0-8
Lifting and Jacking .................................................0-0-9
Safety ......................................................................0-9
Jacking Points ........................................................0-0-9
Lifting.....................................................................0-0-9
Workshop Hoist.....................................................0-9
Workshop Jack.......................................................0-9
Stands....................................................................0-9
Vehicle Recovery..................................................0-0-10
General ................................................................. 0-10
Transporting .........................................................0-10
Suspended Towing...............................................0-10
Adhere to Towing Regulations..............................0-10
Towing by Another Vehicle..................................0-10
Vehicle Identification Number ............................0-0-11
VIN Number Location..........................................0-11

Welcome
0-0-6 Workshop Manual October 2005
Welcome
This Workshop Manual is part of a suite of technical manuals
provided for V8 Vantage. Other technical manuals include:
• Parts manual
• OBDII Diagnostic manual
• Man hour schedules
Chapters
Each chapter in this workshop manual is associated with a 4
digit number, i.e. Transmission (07.00). Each chapter is then
further broken into sections, i.e. Automatic Transmission
(07.01).
Chapter Navigation
Example 1:
Older workshop manuals would have Steering and
Suspension together in one chapter. The structure now used
places Steering and Suspension into their own chapters.
When required references are made out to other chapters.
Page Numbering
The page numbering system used within this workshop
manual is as follows:
Systems Classification Coding
Alongside the ‘System’ and ‘Subsystem’ section titles appear
codes. For example Exhaust ‘09.00’ or Power Steering
‘11.02’. These codes relate to a Corporate Product Systems
Classification (CPSC) and are designed to segregate the parts
for engineering release and organise a variety of engineering
data.
Special Tools
Where special service tools are required to perform an
operation, the tool number is recorded at the point of use
within the procedure. Where the operation of a special
service tool is complicated or not obvious, refer to Appendix
and Glossary for detailed operation procedures. A pictorial
list of special service tools available for this vehicle can also
be found in Appendix and Glossary.
Location References
References to left, right, front or rear of the vehicle or of a
component are referenced from sitting in the drivers seat
facing forward. Any such references to assemblies removed
from the vehicle are to the normal orientation of the
assembly when installed in the vehicle.
The following Warnings, Cautions and Notes are used within
this Owner’s Guide to call your attention to specific types of
information.
Warnings, Cautions and Notes
Warnings
Cautions
Notes
Repairs and Replacements
Where replacement parts are required, it is essential that
only genuine Aston Martin parts are used. Your attention is
drawn to the following points concerning repairs and the
fitting of genuine Aston Martin parts and accessories:
• Safety features embodied in the vehicle may be impaired
if other than genuine Aston Martin parts are installed. In
certain territories, legislation prohibits the fitting of parts
which are not produced to the manufacturers
specification
• Adhere to torque wrench settings given in this manual
• Locking devices, where specified, must be installed. If the
efficiency of a locking device is impaired during removal,
it must be renewed
• The vehicle warranty may be invalidated by the
installation of other than genuine Aston Martin parts
3- 2- 5
System, i.e. Engine system
Subsystem, i.e. Engine lubrication system
Page Number, i.e. Number within subsystem
Warning
Identifies procedures which must be followed precisely
to help avoid the risk of personal injury.
Caution
Provided to indicate procedures which must be followed
precisely to reduce the possibility of damage to the
vehicle.
Provided to indicate procedures which will help to avoid
difficulties in the operation of the vehicle.

Safety Precautions
October 2005 Workshop Manual 0-0-7
Safety Precautions
All service workshops are a source of potential danger and
repair work should only be performed by technically trained
staff following procedures detailed in this manual. A safety
conscious approach to the performance of all service
procedures must be observed at all times. Statutory
requirements governing all aspects of health and safety at
work including directives for the proper use of materials and
equipment must be implemented.
The following contains a list of particular safety precautions
which should be observed; it is not intended to be
exhaustive.
Battery Disconnection
When a service manual procedure requires the vehicle
battery to be disconnected - always physically disconnect
the vehicle battery earth (Negative) lead.
Do not use the ‘Battery Disconnect Switch’.
After reconnecting the vehicle battery the following items
will have to be reset or re-learnt:
•Radiopre-sets
•Windows
• DTCs will be lost
Air Conditioning (A/C) System
Do not break into the A/C refrigeration system until the
refrigerant has been evacuated using the procedure detailed
in this manual. Do not disconnect any A/C refrigerant system
pipes unless trained and instructed to do so. The refrigerant
used can cause blindness if allowed to contact your eyes.
Chemical Handling and Storage
Chemicals used in the servicing of motor vehicles include
acids, adhesives, antifreeze, brake fluids, coolants, grease,
oil, paint, resin and solvents. Exposure to certain chemicals
through direct contact or inhalation can be fatal.
Potential hazards may also be present through the incorrect
use, storage and handling of chemicals causing a fire risk.
The following precautions should be observed.
• Strictly adhere to handling and safety information found
on containers and labels.
• Do not store chemicals in unlabelled or incorrectly
labelled containers.
• Containers used for storing chemicals should not be left
open; there is a risk of spilling, or evaporation of fumes
which may be inflammable or toxic.
• Do not mix chemicals unless instructed to do so following
manufacturers guidelines.
• Do not inhale chemical materials to determine identity,
they may be toxic.
• Do not use petrol, kerosene, diesel fuel, gas oil, thinners
or solvents for washing skin.
• Containers whose capacity is over 25 litres (5 gallons)
require a bund wall in order to contain spillages.
• Chemicals based on solvents such as paint should not be
sprayed in a confined space; work areas used for such
operations should be well ventilated and fume extraction
equipment should be utilised.
• Ensure that adequate ventilation is provided when volatile
de-greasing agents are being used.
• Avoid splashing the skin, eyes and clothing.
• Clean chemicals from the skin and clothing as soon as
possible after soiling.
• Wear protective clothing such as goggles, non porous
gloves and apron when handling battery acid and other
corrosive and toxic substances.
Electrical Equipment
• Ensure that electrical equipment is in safe working order
before use.
• Inspect power leads of all mains electrical equipment for
damage and security, and check that it is properly
earthed.
• Ensure that electrical equipment is protected by a fuse of
the correct current rating.
• Disconnect the battery before commencing repair
operations to the electrical system, fuel system and engine
or when working beneath the vehicle.
Exhaust Fumes
Engines should not be run in confined spaces, exhaust fumes
contain harmful and toxic substances including carbon
monoxide which can prove fatal if inhaled. Engines must
only be run where there is fume extraction equipment in
operation or where there is adequate ventilation.
Fire Precautions
• Ensure that a suitable form of fire extinguisher is
conveniently located near the work area.
• Keep oils, solvents and combustible materials away from
naked flames and other sources of ignition.
• Ensure that NO SMOKING signs are posted around areas
where combustible materials and vapour may be present
and ensure that the warnings are strictly observed.
• Ensure that dry sand is available to soak up any spillage of
fuel or other flammable solutions.
• Fume extraction equipment must be available and in full
working order to remove combustible and toxic vapours.
• All personnel should be aware of the fire drill procedures
and precautions.
Warning
Do not smoke in the vicinity of volatile de-greasing
agents.
Warning
Fume extraction equipment must be in operation when
solvents are used e.g. trichloroethane, white spirit,
SBP3, methylene chloride, perchlorethylene.

Safety Precautions
0-0-8 Workshop Manual October 2005
Tools and Equipment
• Do not leave tools, equipment, spilt oil, etc. around or on
the work area.
• Ensure that tools and equipment used are in good
condition; do not use damaged or defective tools or
equipment.
• Do not apply heat in an attempt to free stiff nuts or fittings;
as well as causing damage to protective coatings, the stray
heat may damage electronic equipment, harnesses and
brake lines.
• Use the recommended service tool where instructed to do
so.
Used Engine Oil
Prolonged and repeated contact with mineral oil will result
in the removal of natural fats from the skin, leading to
dryness, irritation and dermatitis. In addition, used engine
oil contains potentially harmful contaminants which may
cause skin cancer. Adequate means of skin protection and
washing facilities should be provided.
Health protection precautions
• Avoid prolonged and repeated contact with oils,
particularly used engine oil.
• Wear protective clothing, including impervious gloves
where practicable.
• Do not put oily rags in pockets.
• Avoid contaminating clothes with oil.
• Overalls must be cleaned regularly. Discard un-washable
clothes and oil impregnated footwear.
• First aid treatment should be obtained immediately for
open cuts or wounds.
• Use barrier creams, apply before each work period to help
the removal of oil from the skin.
• Wash with soap and water to ensure all oil is removed.
Preparations containing lanolin replace the natural skin
oils which have been removed.
• Do not use petrol, kerosene, diesel fuel, gas oil, thinners
or solvents for washing skin.
• If skin disorders develop, obtain medical advice.
• Where practicable, degrease components prior to
handling.
• Where there is a risk of eye contact, eye protection should
be worn. In addition, an eye wash facility should be
provided.
Environmental Protection
It is illegal to pour used oil on the ground, down sewers or
drains, or into water courses. The burning of used engine oil
in small space heaters or boilers is not recommended unless
emission control equipment is installed; in case of doubt,
contact the Local Authority for advice on disposal facilities.

Lifting and Jacking
October 2005 Workshop Manual 0-0-9
Lifting and Jacking
Safety
• Recommended procedures for lifting, jacking and
towing must be strictly observed to ensure personal
safety.
• Always use a vehicle hoist, ramp or pit for working
beneath the vehicle in preference to jacking.
• Never rely on a jack to support a car independently, use
axle stands or blocks carefully placed at jacking points
to provide rigid support.
• When working beneath a vehicle, chock wheels as well
as applying handbrake.
• Ensure vehicle is standing on firm, level ground before
jacking or lifting.
• Check lifting equipment has adequate capacity for load
being lifted and is in full working order.
Jacking Points
This vehicle jacking points are at positions shown.
May also be jacked on the front subframe front crossmember
Always use a jack with a rubber contact pad. Avoid use of
jacks with sharp contact pads which would damage floor
pan Always chock the opposite road wheels as well as
applying the handbrake when using a hydraulic jack.
To prevent body distortion, avoid single point or one side
jacking with the tunnel shear panel removed.
Lifting
Workshop Hoist
Use of a workshop hoist is recommended for all operations
where vehicles must be raised. Follow manufacturers
instructions. If using an adjustable arm type, ensure lifting
pads are correctly positioned at the four jacking points
before lifting.
Workshop Jack
To avoid any danger of bodywork damage when using a
hydraulic jack, the vehicle must only be lifted at the jacking
points.
Stands
When carrying out work (other than a wheel change) which
requires a wheel to be raised, a stand must be used, located
at the jacking point, to provide a secure support for the
vehicle.


Vehicle Recovery
0-0-10 Workshop Manual October 2005
Vehicle Recovery
General
Preferred method of vehicle recovery is by flat bed
transporter.
The towing eye is primarily for emergency use when towing
for short distances, e.g. removing vehicle if it is causing an
obstruction or winching vehicle onto a flatbed transporter.
If moving this vehicle in such a situation, install the towing
eye to the bracket in the lower grille aperture.
Transporting
If vehicle is to be transported on a trailer or flat bed
transporter the handbrake must be applied and the road
wheels must be chocked.
Suspended Towing
Take care when using 'spectacle frame' type towing
equipment that the towing device is well clear of front or
rear apron. Body damage may occur if vehicle passes over
uneven road surfaces.
Rear Suspended Tow
1. Set the steering in the ‘straight ahead’ position.
Remove the ignition key from the ignition. Ensure the
steering is locked in the straight ahead position.
2. Raise the vehicle using a 'spectacle frame' style lifting
device where a cradle is positioned under each rear
wheel as indicated below.
Adhere to Towing Regulations
In certain countries the registration number of towing
vehicle and an ‘ON TOW’ sign or warning triangle must be
displayed in a prominent position at the rear of vehicle being
towed.
Towing by A nother Vehicle
This vehicle may be towed short distances by another
vehicle provided that a speed of 48 km/h (30 mph) is not
exceeded. Ensure the towed vehicle gear selection is in
‘Neutral’ (manual) or position ‘N’ (automatic) with ignition
key turned to position ‘II’ to release steering lock and to
render horn, indicators and brake lights operational.
Caution
Take care to protect the paint work when installing the
towing eye. Ensure the towing eye is tight.
Caution
Do not tow with ‘sling’ type equipment as this
could result in damage to the bodywork.
Warning
When the engine is not running, the steering will no
longer be power-assisted and the brake booster will
become ineffective after a few applications of the
brakes. Be prepared for relatively heavy steering and
the need for greatly increased brake pedal pressure.

Vehicle Identification Number
October 2005 Workshop Manual 0-0-11
Vehicle Identification Number
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.
VIN Number Location
The VIN number is shown on two labels in the vehicle:
1 Under the lower edge of the windscreen.
2 Front of the engine bay.
• The VIN number is also engraved on the floorpan in the
right front footwell.
SCFBC3A45GC00001
Code for AML
Restraint System
Transmission and Steering
Body Type
Engine Type
Calculated Check Digit
Model Year
Manufacturing Plant
Series Identifier
Sequential Chassis Number

Body System (01.00)
Contents
Body Structure (01.01)...........................................1-1-3 Undertray Vehicle Set-Renew ................................ 5-2
5-2
Overview ................................................................ 1-3 RH/LH Front Wheel Arch Liner-Renew ..................
Front End (01.02)...................................................1-2-1 RH/LH Rear Wheel Arch Liner-Renew ................... 5-2
Front Wings ............................................................2-1
Specifications.........................................................2-1 Specifications ......................................................... 6-1
Body Closures (01.03) ...........................................1-3-1 Maintenance........................................................... 6-1
6-1
6-1
Tailgate..................................................................3-1
7-1
7-1
7-1
7-1
Specifications..........................................................3-1 RH/LH Door Mirror Assembly-Renew ....................
Doors .................................................................... 3-1 Door Mirror Glass and Pad Assembly-Renew .........
Bonnet................................................................... 3-1 Description.............................................................
Maintenance...........................................................3-2 Heated Seats .........................................................
Tailgate Assembly-Renew.......................................3-2 Specifications ........................................................
Hood Assembly-Renew..........................................3-2 Maintenance...........................................................
Interior Trim (01.05)..............................................1-4-1
Maintenance...........................................................4-1
Rear Centre Console-Renew 8-1
8-1
8-1
8-1
8-1
8-1
8-1
8-2
8-2
Door Trimboard Assembly-Remove for Access/Refit4-3
9-1
9-1
........................................ 9-1
9-6
9-6
9-6
.......................... 9-6
new ....................................................................... 4-5
9-7
9-7
9-8
.................................... 9-8
9-8
......................................... 9-9
..................................4-1 Description.............................................................
RH/LH Front Sill Plate-Renew ................................4-1 Frameless doors .....................................................
RH/LH Front Sill Name Plate-Renew ...................... 4-1 Specifications.........................................................
Header Panel Assembly-Renew..............................4-1 Maintenance...........................................................
RH/LH Upper Rear Pillar Panel Assembly-Renew ... 4-2 Glass Regulator ......................................................
RH Sun Visor-Renew .............................................4-2 RH/LH Door Glass-Renew .....................................
LH Sun Visor-Renew..............................................4-2 Door Glass-Adjust/Reset.........................................
Rear Header Panel Assembly-Renew......................4-3 Front Windshield-Renew .......................................
Door Trimboard Assembly-Renew..........................4-3 Rear Windshield-Renew ........................................
RH/LH Door Trim Upper Veneer Panel-Renew ...... 4-4 Specifications .........................................................
LH Door Trim Upper Panel-Renew........................ 4-4 Maintenance...........................................................
RH/LH Interior Door Assembly Handle and Armrest-Re- Instrument Panel-Renew
new ....................................................................... 4-4 Driver Upper Inner Panel Assembly-Renew............
RH/LH Door Pocket Assembly-Renew....................4-4 Driver Outer Upper Panel Assembly-Renew ..........
Lower Panel Assembly Quarter Trim-Renew ..........4-4 Passenger Upper Panel Assembly-Renew ...............
RH/LH Middle Section Quarter Trim Panel Assembly-Re- Passenger Panel Assembly-Renew
RH/LH Upper Quarter Moulding Trim-Renew........4-5 Driver Lower Panel Assembly-Renew.....................
RH/LH Rear Heel Board Assembly-Renew..............4-5 Airbag Panel and Door Assembly-Renew ...............
Tailgate Lid Trim Assembly-Renew.........................4-5 Instrument Cluster Hood Assembly-Renew.............
RH/LH Side Luggage Compartment Carpet Assembly-Re- Glovebox Assembly-Renew
new ....................................................................... 4-5 Knee Protector-Renew...........................................
Luggage Compartment Front Carpet Assembly-Renew4-6 Glovebox Shield-Renew
Mirrors (01.09) ......................................................1-6-1
Seating (01.10).......................................................1-7-1
RH/LH Front Seat-Renew....................................... 7-1
Glass, Frame and Mechanism (01.11)...................1-8-1
Instrument Panel (IP) (01.12)................................1-9-1
............... Passenger Lower Panel Assembly-Renew9-7
Luggage Compartment Floor Rear Carpet Assembly-Renew Glove Compartment Damper Spring-Renew .......... 9-9
4-6 Cluster Bezel Panel-Renew .................................... 9-9
9-10
9-10
9-10
Tailgate Scuff Plate-Renew .....................................4-6 Driver Panel Assembly-Renew .............................
LH Side front Carpet Assembly-Renew ...................4-6 Instrument Panel Bezel Assembly-Renew .............
Centre Stack Assembly-Remove for Access/Refit..... 4-6 Radio Speaker Grille Assembly-Renew .................
Exterior Trim (01.08) .............................................1-5-1
Maintenance 9-11
9-11
9-11
9-11
9-11
RH Wing Side Strake-Renew..................................5-1
10-1
10-1
10-1
...........................................................5-1 Console Panel Assembly-Renew...........................
Radiator Grille-Renew............................................5-1 Master Lock Switch-Renew ..................................
RH/LH Hood Mesh Assembly-Renew..................... 5-1 IDV Control Switch-Renew ..................................
RH Side Strake Mesh-Renew.................................. 5-1 Heated Front Screen Switch-Renew.....................
LH Side Strake Mesh-Renew..................................5-1 PDC Off Switch-Renew .......................................
LH Wing Side Strake-Renew ..................................5-1 Description...........................................................
Front Undertray-Renew .........................................5-2 Vehicle Key/Remote Transmitter ..........................
Rear Undertray-Renew .......................................... 5-2 Central Locking System........................................
Glovebox Open Switch-Renew............................ 9-11
Handles and Lock Mechanisms (01.14) ..............1-10-1
October 2005 Workshop Manual 1-1-1

Remote Transmitter..............................................10-1
Fuel Filler Assembly..............................................10-1
Boot Emergency Release ......................................10-1
Specifications........................................................10-2
Maintenance .........................................................10-2
RH/LH Front Door Latch Assembly-Renew ...........10-2
0114BD|Latch Assembly - Hood - Renew............10-2
RH/LH External Front Door External-Renew .........10-2
Reduced Guard Switch-Renew.............................10-3
Passenger Airbag On/Off Switch-Renew ...............10-3
Tailgate Release Switch-Renew.............................10-3
Passenger Window Lift Switch-Renew ..................10-3
Driver Window Lift Switch-Renew........................10-3
Wipers and Washer System (01.16).................... 1-11-1
Headlamp Washing ..............................................11-1
Windscreen Reservoir and Motor Assembly-Renew11-3
Headlamp Wash Motor and Pump Assembly-Renew11-4
Specifications........................................................11-2
Maintenance .........................................................11-2
Windscreen Wiper Motor Assembly-Renew..........11-2
Wiper Linkage Assembly-Renew...........................11-2
Driver Wiper Arm Assembly-Renew .....................11-2
Passenger Wiper Arm Assembly-Renew................11-3
Windshield Wash Filler Neck-Renew....................11-3
Low Level Water Sensor-Renew ...........................11-3
Washer Fluid Reservoir-Renew.............................11-4
Bumpers (01.19) ................................................. 1-12-1
Front Bumper........................................................12-1
Rear Bumper.........................................................12-1
Specifications........................................................12-2
Maintenance .........................................................12-2
Front Bumper Cover-Renew.................................12-2
Rear Bumper Cover-Renew..................................12-2
RH/LH Rear Lower Bumper Mesh-Renew.............12-3
Rear Diffuser-Renew ............................................12-3
Rear Lower Assembly Centre Mesh-Renew...........12-3
Restraining Devices (01.20)................................ 1-13-1
Seat Belts...............................................................13-1
Emergency Locking Retractor (ELR).......................13-2
Airbag System .......................................................13-3
Maintenance .........................................................13-4
Driver’s Airbag Module-Renew.............................13-4
Passenger Airbag-Renew.......................................13-4
Side Impact Door ARS Sensor Assembly-Renew....13-5
1-1-2 Workshop Manual October 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.
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
October 2005 Workshop Manual 1-1-3

Body Structure (01.01)
Body System (01.00)
1-1-4 Workshop Manual October 2005

Front End (01.02)
Body System (01.00)
Body System (01.00)
Front End (01.02) Wing Standard (mm)
Item 1 2 3 4
Front Wings Tolerance ±0.75 +0.5 / -0.0 ± 0.75 ±0.5
Specifications Flush -0.0 0.0 0.0 -0.5
Tolerance ±1.5 +0.0 / -0.5 ±1.5 ±0.5
Taper N/A
Symmetry N/A
Torque Figures
Description Nm
Wing Top 8
Wing Top Single nut Tight with
‘Threadlock’
Lower Rear 8
Slam panel 8
PCM Bracket 10
Bonnet Damper 25
Wing Standard (mm)
1
2
4
3
Item 1 2 3 4
Nominal gap 3.5 2.0 3.75 3.0
October 2005 Workshop Manual 1-2-1

Front End (01.02)
Body System (01.00)
1-2-2 Workshop Manual October 2005

Body Closures (01.03)
Body System (01.00)
Body System (01.00)
Body Closures (01.03) Tailgate
Specifications
Doors
2
1
Tailgate Standard (mm)
Door Standard (mm) Item 1 2
Item 1 *2 3 4 Nominal gap 3.5 3.5
Nominal gap 3.5 3.00 3.00 3.75 Tolerance ±0.75 ±1.0
Tolerance ±0.75 ±1.0 ±1.0 ± 0.75 Flush -0.5 N/A
Flush 0.0 -1.0 -1.0 0.0 Tolerance +0.5 / -1.0 N/A
Tolerance ±1.5 / 0.0 +0.0 / -1.0 ±1.0 ±1.5 Taper 1 mm Max. across the length
Taper N/A Symmetry 1 mm Max. difference LH to RH
Symmetry N/A
* Flushness blends to 0.0 at the rear quarter Torque Figures
* Gap blends to 3.5 at rear quarter Description Nm
Hinge to Body 25
Torque Figures Bonnet
Description Nm.
Hinge to Door 47.5
Hinge to Body 36
Door Striker plate
1
Bonnet Standard (mm)
Item 1
Nominal gap 3.5
Tolerance ±0.75
Flush -0.0
Toleranc e ±1.5
Taper N/A
Symmetry N/A
Torque Figures
Description Nm.
Hinge to Body 25
October 2005 Workshop Manual 1-3-1

Body Closures (01.03)
Body System (01.00)
Maintenance Installation
Tailgate Assembly-Renew 1. Position hood to hinge and install bolts (x4).
2. Install hood ball studs.
Repair Operation Time (ROT)
Item Code
Tailgate Assembly-Renew 01.03.GG
3. Install Buffers to hood.
4. Install sound deadening.
5. Align hood to aperture.
Removal 6. Raise hood. Nip up one hinge bolt either side.
1. Remove RH quarter upper trim panel (see Workshop 7. Lower hood and check alignment.
Manual Procedure 01.05.CX Moulding Assembly - 8. Raise hood and tighten hinge bolts (x4) and tighten.
Quarter Trim Upper - RH - Renew). 9. Install gas struts.
2. Remove LH quarter upper trim panel. 10. Close bonnet to check engagement of latch assembly,
3. Remove rear header trim panel. adjust if necessary.
4. Disconnect LH and RH tailgate harnesses in cabin 11. Close hood and check operation of hood release lever.
5. Remove LH and RH harness grommets from body shell
6. Remove tailgate trim panel (see Workshop Manual
Procedure 01.05.EF Trim - Tailgate Lid Assembly -
Renew).
7. Disconnect one multiplug and remove securing bolts
(x3) for GPS aerial and place to one side.
8. Disconnect multiplug and remove securing nuts (x2) for
central high stop lamp assembly, place to one side.
9. Disconnect multiplug and remove securing nuts (x2) for
tailgate release switch, place to one side.
10. Remove tailgate buffer stops and place to one side.
11. Provide collision protection between tailgate corners
and bodywork.
12. With assistance remove bolts (x4) from hinges and place
tailgate to one side.
Installation
1. With assistance align tailgate to hinges and install bolts
(x4), nip but do not tighten.
2. Adjust alignment of tailgate and tighten hinge bolts.
3. Install tailgate buffers and adjust height as necessary
4. Install tailgate release switch and secure with nuts (x2),
connect multiplug.
5. Install central high level stop lamp assembly, secure with
nuts (x2) and connect multiplug.
Hood Assembly-Renew
Repair Operation Time (ROT)
Item Code
Tailgate Assembly-Renew 01.03.AB
Removal
1. Open hood.
2. Disconnect windscreen wash pipe.
3. Remove ball studs from hood.
4. Remove buffers from hood.
5. Remove hood sound insulation.
6. Loosen hood hinge bolts (4).
7. Disconnect gas struts and remove hinge bolts.
8. Remove hood.
1-3-2 Workshop Manual October 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 moldings 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.
Maintenance
Rear Centre Console-Renew
Repair Operation Time (ROT)
Item Code
Rear Centre Console-Renew 01.04.BB
Removal
1. Remove storage compartment door.
2. Remove bolt and screws (x5) from storage compartment
support rail.
3. Release and remove centre arm rest (see Fig. 1).
Fig. 1
4. Install storage compartment door.
RH/LH Front Sill Plate-Renew
Repair Operation Time (ROT)
Item Code
Front Sill Plate-Renew
Front Sill Plate-Renew
RH
LH
01.05.AJ
01.05.AK
Removal
1. Remove screws (x2) name plate to front plate.
2. Remove bolts (x6) front plate to sill.
3. Remove front plate
Installation
1. Position front plate and install bolts (x6).
2. Install front sill name plate.
RH/LH Front Sill Name Plate-Renew
Repair Operation Time (ROT)
Item Code
Front Sill Name Plate-Renew
Front Sill Name Plate-Renew
RH
LH
01.05.AL
01.05.AM
Removal
1. Remove screws (x2) name plate to front plate.
2. Remove name plate.
Installation
4. Remove nuts (x3), screws (x4) from panel assembly rear 1. Install name plate to front plate.
console (see Fig. 2). Header Panel Assembly-Renew
Fig. 2
Repair Operation Time (ROT)
Item Code
Header Panel Assembly-Renew 01.05.BB
Removal
1. Remove grill from front header courtesy light console.
Installation
1. Install panel and tighten nuts (x3) and screws (x4).
2. Install centre arm rest.
3. Install support rail and tighten screws (x5) and bolt.
October 2005 Workshop Manual 1-4-1