2010 ASTON MARTIN V8 VANTAGE Clutch hydraulic system

May 2007 Workshop Manual 8-1-1
Clutch (08.00)
Contents
Clutch Assembly (08.01)........................................ 8-1-2Description ............................................................. 1-2
Specifications.......................................................... 1-2
Maintenance ........................................................... 1-2 Clutch and Flywheel Assembly-Renew ................... 1-2
Slave Clutch Cylinder-Renew ................................. 1-3
Clutch Bleed Hose Assembly-Renew ...................... 1-4
Clutch Hydraulic System-Bleed-Sportshift Only ...... 1-4
Clutch Hydraulic System-Bleed .............................. 1-5
Master Cylinder to Slave Cylinder Tube
Assembly-Renew-Sportshift Only............................ 1-5

Clutch Assembly (08.01)
8-1-2 Workshop Manual May 2007
Clutch (08.00)
Clutch Assembly (08.01)
Description
The clutch assembly consists of a balanced flywheel, a clutch
driven plate and a clutch cover.
The clutch is a single plate, diaphragm spring type assembly.
A concentric clutch slave cylinder is mounted around the
first motion shaft in the torque tube bell housing.
The clutch master cylinder is mounted on the engine
bulkhead and is operated directly by the clutch pedal.
A hydraulic connection from the master cylinder feeds
pressurised fluid to the slave cylinder. The slave cylinder has
an extension tube and bleed nipple extending from the left
side of the bell housing for bleeding the system after any
major work.
Specifications
Maintenance
Clutch and Flywheel Assembly-Renew
08.00.AA
Removal
1. Disconnect vehicle battery.
2. Raise vehicle on ramp.
3. Remove torque tube assembly (see Workshop Manual procedure 05.01.CA Torque Tube Remove for Access
and Refit).
4. Remove bolts (x2) from inspection cover to lower crankcase and remove cover. 5. Install special tool SKAM14546 OT to restrain flywheel
and install and tighten bolts (x2) (see Fig. 1).
6. Remove bolts (x6) from clutch cover to flywheel (see Fig.
2).
7. Release clutch cover from dowels, remove cover and collect drive plate.
Clutch Fluid
Castrol/Girling Universal Brake and Clutch fluid.
Clutch Assembly
Clutch and flywheel are separately balanced.
Clutch Plate
Single 267mm driven plate.
Torque Figures
DescriptionNmlb/ft
Flywheel Bolts
Tighten the bolts in sequence. Loosen
the bolts and then torque, in even
stages, in the same sequence. 100 -
120
74-
88.5
Clutch Bolts
Tighten x6 equally-spaced bolts, in-
turn, to pull-down the clutch evenly.
Then torque all bolts in sequence. 65-75 48-55
Starter Motor Bolts 42.5-
57.531.5-
42.5
Repair Operation Time (ROT)
Fig. 1
Fig. 2
Warning
The clutch assembly is heavy. Ensure the clutch
assembly is supported befo re removing final bolts.



Clutch Assembly (08.01)
8-1-4 Workshop Manual May 2007
8. Remove bolts (x2) that secure slave cylinder to torque tube (see Fig. 2).
9. Remove slave cylinder and collect spacer.
Installation
1. Clean slave cylinder, spacer and pipe adaptors.
2. Install spacer and slave cylinder and tighten bolts (x2).
3. Sportshift Only - Install clutch position sensor to slave
cylinder and secure with bolts.
4. Install pipe adaptors (x2) in slave cylinder.
5. Install bleed and supply pipes onto slave cylinder adaptors (x2) and secure with clips.
6. Install torque tube (see Workshop Manual procedure 05.01.CA Torque Tube Remove for Access and Refit).
7. Bleed clutch (see Workshop Manual procedure 08.00.AF Clutch Hydraulic System - Bleed).
8. Lower vehicle on ramp.
9. Connect vehicle battery.
Clutch Bleed Hose Assembly-Renew
08.00.AD
Removal
1. Raise vehicle on ramp.
2. Coupe Only - Remove deflector - front floor heatshield
(see Workshop Manual proc edure 09.04.AA Heatshield
- Front Floor - Renew).
3. Roadster Only - Remove exhaust sysytem (see
Workshop Manual procedure 09.00.NB Exhaust System
- Excluding manifold/down pipes - Renew). 4.
Roadster Only - Remove grommet sealing clutch bleed
pipe to torque tube.
5. Roadster Only - Position a piece of cloth in torque tube
aperture to collect spring clip (if dropped) and fluid loss.
6. Release clip and disconnect bleed hose from slave cylinder adaptor.
7. Plug slave cylinder to prevent fluid loss.
8. Release and remove bleed pipe assembly from support bracket.
Installation
1. Clean bleed hose assembly.
2. Remove plug from slave cylinder adaptor.
3. Install bleed hose and secure with clip.
4. Install bleed hose in support bracket.
5.Roadster Only - Install grommet sealing clutch bleed
pipe to torque tube.
6. Bleed clutch (see Workshop Manual procedure 08.00.AF Clutch Hydraulic System - Bleed).
7. Roadster Only - Install exhaust sysytem (see Workshop
Manual procedure 09.00.NB Exhaust System -
Excluding manifold/down pipes - Renew).
8. Coupe Only - Install deflector - front floor heatshield
(see Workshop Manual procedure 09.04.AA Heatshield
- Front Floor - Renew).
9. Lower vehicle on ramp.
Clutch Hydraulic System-Bleed-
Sportshift Only
08.00.AE
1. Raise vehicle on ramp.
2. Install Diagnostic tool and navigate to appropriate screen.
3. Position cloth around fluid reservoir to collect any spillage.
4. Remove fluid reservoir cap, en sure fluid level is correct
in reservoir.
5. Clean area around clutch bleed nipple.
6. Remove cap from bleed nipple.
7. Position bleed container containing clean hydraulic fluid, connect hose to bleed nipple.
8. Initiate bleed procedure on Diagnostic tool.
9. Loosen bleed nipple, allow air/fluid to escape and tighten bleed nipple.
10. Repeat procedure until air free fluid emerges.
11. Disconnect bleed hose, remo ve container, install dust
cap to bleed nipple.
12. Top-up fluid reservoir.
Fig. 2Warning
Always connect the battery earth (+ve) terminal first.
Repair Operation Time (ROT)
Before proceeding with the ne xt step, position a piece of
cloth in the torque tu be aperture to collect the spring clip
if dropped.
Caution
Always plug pipe ends to prevent ingress of dirt or moisture into the system.

Repair Operation Time (ROT)
ItemCode
Clutch Hydraulic System-Bleed
Warning
Observe all oil/fluid manufactu rers safety instructions
when handling components th at have been in contact
with transaxle oil.

Clutch Assembly (08.01)
May 2007 Workshop Manual 8-1-5
13. Remove Diagnostic tool.
14. Lower vehicle on ramp.
Clutch Hydraulic System-Bleed
08.00.AF
1. Raise vehicle on ramp.
2. Remove fluid reservoir cap and ensure fluid level is correct.
3. Clean area around clutch bleed nipple.
4. Remove cap from bleed nipple.
5. Position bleed container cont aining clean hydraulic fluid
and connect hose to bleed nipple.
6. Depress clutch pedal to floor 3 times and hold pedal down on third application.
7. Loosen bleed nipple allowing any air/fluid to escape.
8. Tighten bleed nipple.
9. Repeat procedure until air-free fluid emerges.
10. Disconnect bleed hose, remove container and install dust cap to bleed nipple.
11. Top-up fluid reservoir.
12. Lower vehicle on ramp.
Master Cylinder to Slave Cylinder Tube
Assembly-Renew
08.00.AJ
-Sportshift Only
Removal
1. Disconnect vehicle battery. 2. Raise vehicle on ramp.
3. Remove torque tube (see Workshop Manual procedure
05.01.CA Torque Tube - Remo ve for Access & Refit).
4. Remove grommet sealing clutch pipe to torque tube.
5. Remove clip, disconnect clutch pipe from slave cylinder adaptor.
6. Release clip securing transmi ssion harness to clutch pipe
mounting bracket.
7. Release clips (x4) securing clutch pipe to transmission harness.
8 . R e m o v e c l u t c h p i p e f r o m t o r q u e t u b e .
Installation
1. Install clutch pipe to torque tube.
2. Secure clutch pipe to tran smission harness using clips.
3. Secure transmission harne ss to clutch pipe mounting
bracket using clip.
4. Install clip and refit clutch pipe to slave cylinder adaptor.
5. Install grommet sealing clutch pipe to torque tube.
6. Install torque tube (see Workshop Manual procedure 05.01.CA Torque Tube - Remo ve for Access & Refit).
7. Bleed clutch hydraulics (see Workshop Manual procedure 08.00.AE Clut ch Hydraulic System -
Sportshift - Bleed).
8. Lower vehicle on ramp.
9. Connect vehicle battery.
Repair Operation Time (ROT)
Warning
Avoid skin / eye contact or in gestion of clutch fluid. If
skin or eyes are sp lashed with clutch fluid, rinse the
affected area immediately with plenty of water and
obtain medical attention. If clutch fluid is ingested, obtain immediate medical attention.
Caution
Clutch fluid must not be allowed to contact vehicle paint work. Remove spilt clutch fl uid from the paint work by
rinsing away with running water.
Warning
Brake / Clutch fluid is hygroscopic. If kept in opened
containers it will absorb water vapour. Use only brake
fluid from freshly opened co ntainers when topping-up
the brake fluid reservoir.
Before proceeding to the next step, position cloth around
fluid reservoir to collect any spillage.
Repair Operation Time (ROT)
Warning
Always disconnect the battery earth (- ve) terminal first.
Warning
When raising the vehicle on a ‘two post’ ramp, ensure
that the rear end of the vehicle is securely strapped to
the ramp. Failure to strap the rear of the vehicle down may lead to the vehicl e falling off the ramp.
Warning
Observe all oil/fluid manufact urers safety instructions
when handling components that have been in contact with transaxle oil.
Warning
Always connect the battery ea rth (+ve) terminal first.

AML EOBD System Operation Summary

Rory O’Curry Aston Martin Lagonda CONFIDENTIAL 1 May 2009
[email protected] AML EOBD Monitors 07 ROC.doc Page 34 of 43

6HP26 Automatic Transmission


This transmission is operated by a stand-alone transmission control module (TCM). The MIL related
Diagnostic Trouble Codes will be transmitted via CAN to the Engine Control Module (ECM), and the
MIL illuminated, for all emissions related electrical and mechanical component malfunctions. For
malfunctions attributable to a mechanical component, this transmission may be capable of not
commanding the mechanically failed component a nd providing the remaining maximum functionality
(functionality may be reassessed on each power up). The TCM may be interrogated for transmission
information attributable to setting either code. The TCM Diagnostic Trouble Codes are addressed via a
separate document enclosed.







Auto Shift Manual (ASM) Transmission

The ASM system is based around a standard manual transmission with a clutch and mechanical selection
of a set range of gear ratios (in this case 6 speeds). In this application both clutch and gear selection
operations are controlled via a Transmission Contro l Module (TCM) which commands hydraulic actuators
based on commands from a number of inputs.

The driver actions of depressing and releasing the clutch pedal to control clutch actuation and the shifting
of gears using a gear lever have, in essence, been re placed by a TCM, hydraulic actuators and electronic
switches.

With ASM the demand to shift gears can either be direct from the driver (as in a conventional manual
transmission), or controlled automatically by the system based on parameters such as road speed, current
gear selected and throttle demand.

The MIL is illuminated for all emissions related electrical component malfunctions. For malfunctions
attributable to a mechanical component (such as a cl utch, gear, actuator, etc.), functionality is reassessed
on each power up. In such case a non-MIL or MIL Diagnos tic Trouble Code (DTC) will be stored and, if
so equipped, a Transmission Control Indicator Light will activate and/or a message will be displayed. For
example on the ASM transmission, if a gear selection is not properly obtained and verified due to a
mechanical malfunction, then the amber Transmission Control Indicator Light will activate and the
message center will display 'GEARBOX FAULT'. In addition, the powertrain MIL will activate and a
DTC will be stored. The TCM Diagnostic Trouble Cod es are addressed via a separate document enclosed.

Aston Martin V8 Vantage2009MY OBDII Documentation 4.7L Aston Martin Confidential
Component P CodesMalfunction Strategy
Description Malfunction Criteria
(Fault) Fault condition
(Internal labels) Threshold Value
(Fault condition) Entry conditions Entry conditions values Filter Time to
log DTCClutch position sensor P173B S1/ S2 wire short
circuit to battery or open circuit Clutch position sensor -
Secondary Circuit high The asic UH05 inside the TCU
detects the fault and communicate it to the uP
Output Voltage > th_high th_high = 4,5V (Key ON) AND NOT
(cranking) AND
VSupply inside prope
r
range VSupply range = 7V-24.5V 50ms
Clutch position sensor P0805 Short circuit between
P1 and P2 or short
circuit between S1 and S2 Clutch position sensor - Primary
Secondary short circuit The clutch position signal is a fixed
value (around 2.5 V)
See annexed Chart 2 th_1= 5 km/h
th_2= 2000 bit
timeout_1=100ms timeout_2=50ms (Key ON) AND NOT
(cranking) AND
VSupply inside proper
range VSupply range = 7V-24.5V 50ms
Hydraulic
pressure sensor P0935 Hydraulic pressure
sensor short to GND or open circuit Hydraulic pressure signal circuit
high Output Voltage < th_low th_low = 0,39V (Key ON) AND NOT
(cranking) AND
VSupply inside proper VSupply range = 7V-24.5V 500ms
Hydraulic
pressure sensor P0934 Hydraulic pressure
sensor short to battery Hydraulic pressure signal circuit
low Output Voltage > th_high th_high = 4,79V (Key ON) AND NOT
(cranking) AND
VSupply inside proper VSupply range = 7V-24.5V 500ms
Hydraulic
pressure sensor P0932 Internal Sensor
Damage or open
circuit on the ground sensor wire Hydraulic pressure signal wrong
value Wrong constant pressure value
detected through a correlation
between the pressure variation and an estimation of the oil flow (Key ON) AND NOT
(cranking) AND
VSupply inside proper
range VSupply range = 7V-24.5V 500ms
Kl.30 Power Supply P1794 Open circuit or broken
fuse on TCU supply Kl.30 Power Supply open circuit Power Supply < V_th
V_th = 3V (Key ON) AND NOT
(cranking) 500ms
External sensors power supply or sensor ground P0641 Failure of the sensor
power voltage supply External sensors power supply
or sensor ground open circuit or short circuit V_Sensor_Supply inside proper
range V_Sensor_Supply range
= 4V-5V (Key ON) AND NOT
(cranking) AND
VSupply inside proper
range VSupply range = 7V-24.5V 2500ms
Engine speed from CAN U0401 Internal Problem on
Engine Control System Engine ECU: Engine speed fro
m
CAN. Signal not valid
CAN engine sp = inv_th inv_th = FFFFh NOT (Cranking) AND
(ECU ON since t_on)t_on = 200 ms 1000ms
Engine speed from CAN U1900 Internal Problem on
Engine Control System Engine ECU: Engine speed fro
m
CAN. Signal absent (wrong zero
rpm signal) (CAN engine sp = 0) AND (Engine
ON) Engine ON 1000ms
Engine speed from CAN U1920 Internal Problem on
Engine Control System Engine ECU: Engine speed fro
m
CAN. Signal wrong
(CAN engine speed different form
Clutch speed) AND (CAN engine
speed different from Driveline speed x gear ratio) Seed tollerance=
500rpm (Engine ON) AND
(clutch closed) AND (gear engaged) 1000ms
ASM OBD
228/04/2008

Aston Martin V8 Vantage2009MY OBDII Documentation 4.7L Aston Martin Confidential
Component P CodesMalfunction Strategy
Description Malfunction Criteria
(Fault) Fault condition
(Internal labels) Threshold Value
(Fault condition) Entry conditions Entry conditions values Filter Time to
log DTCPump relay P0947 Pump relay connected GNDPump relay Short circuit to GND The asic UH04 inside the TCU
detects the fault and communicate it to the uP
Driver output current > th3 during valve on phase th3= 3.7A
NOT (Cranking) 200ms
Clutch system P186D Clutch or actuator or valve damagedClutch not opening before gear
shifting Clutch not open in a timeout timeout = 500ms (Gear shifting in
progress) AND
(Clutch opening
Gear Box system P1734 Mechanical or hydraulic problemGear Box. Disengage failed
(mechanical causes) Gear not disengaged in a timeout timeout = 500ms (Gear shifting phase)
AND (disengage phase)
Gear Box system P1701 Mechanical or hydraulic problemGear Box. Wrong gear
engagement The gear which is going to be
engaged is not the requested one (Gear shifting phase)
Hydraulic circuit P0868 Hydraulic leakage Hydraulic circuit. Pressure low Comparison between sensor pressure signal and threshold = f(oil temperature)
pressure < th Th= 25 bar @ -30°C
Th= 40 bar @120°C linear interpolation (Engine ON) AND
NOT (cranking) 200ms
Power grounds P1710 Power grounds. Disconnection both ground pins Power grounds. Disconnection
both ground pins The diagnosis is based on the batter
y
voltage modification during the
activation of the clutch electrovalve. Ubatt < Ubatt0 - DltUbatt Ubatt0 = Ubatt before
starting the testDltUbatt = 2,5V Wake-up phase
ASM OBD
628/04/2008